Assembly
1. PRECAUTIONS FOR ASSEMBLING.(1) Assemble in the reverse order of disassembling.
- Check and adjust each part during assembly.
(2) Keep the shims and washers in order, so that they are not misinstalled.
(3) Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed.
(4) Apply gear oil when installing the bearings and thrust washers.
(5) Be careful not to mix up the right and left hand cups of the bearings.
(6) Replace the oil seal with new one at every disassembly. Apply chassis grease between the lips (*) when installing the oil seal.
(7) Do not reuse old gaskets. Install new ones.
2. ADJUSTING PRELOAD FOR FRONT AND REAR BEARINGS.
Adjust the bearing preload with spacer and washer between front and rear bearings. Pinion height adjusting washer has nothing to do with this adjustment. The adjustment must be carried out without oil seal.
(1) Press front and rear bearing cups into differential carrier.
(2) Insert dummy shaft with pinion height adjusting washer and rear bearing cone fitted on it into case. Reuse the used washer if they show normal tooth Contact Pattern when checked before disassembly.
(3) Then, install preload adjusting spacer and washer, front bearing cone, dummy collar, companion flange, washer and drive pinion nut.
Fig. 4 Measuring Pinion Bearing Preload:
(4) Turn dummy shaft with hand to make it seated, and tighten drive pinion nut while measuring the preload with spring balance as shown in the figure. Select preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque.
a. Be careful not to give excessive preload.
b. When tightening the drive pinion nut, lock dummy shaft with block as illustrated.
Torque (Drive pinion nut): 167-196 Nm (123-145 ft.lb)
3. ADJUST DRIVE PINION HEIGHT WITH WASHER INSTALLED BETWEEN REAR BEARING CONE AND THE BACK OF PINION GEAR.
(1) Install dummy shaft, collar and gauge, as shown in the figure, and apply the specified preload on the bearings. (Refer to Step 2. Adjusting preload for front and rear bearings.)
- At this time, install a pinion height adjusting washer which is temporarily selected or the same as that used before.
(2) Measure the clearance N between the end of gauge and the end surface of dummy shaft by using a thickness gauge.
- Make sure there is no clearance between the case and gauge.
(3) Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed washer with this one.
Equation: T = To + N - (H x 0.01)-0.20 (mm) where
T = Thickness of pinion height adjusting washer (mm)
To = Thickness of washer temporarily inserted (mm)
N = Reading of thickness gauge (mm)
H = Figure marked on drive pinion head
Example of calculation
To = 2.20 + 1.20 = 3.40 mm
N = 0.23 mm H = + 1,
T = 3.40 + 0.23-0.01-0.20 = 3.42
Result: Thickness = 3.42 mm
Therefore use the washer 383605200.
4. INSTALL THE SELECTED PINION HEIGHT ADJUSTING WASHER ON DRIVE PINION, AND PRESS THE REAR BEARING CONE INTO POSITION WITH INSTALLER.
5. INSERT DRIVE PINION INTO DIFFERENTIAL CARRIER, INSTALL THE PREVIOUSLY SELECTED PRELOAD ADJUSTING SPACER AND WASHER.
6. PRESS-FIT FRONT BEARING CONE INTO CASE.
7. INSERT SPACER, THEN PRESS-FIT PILOT BEARING WITH WEIGHT AND INSTALLER.
8. FIT A NEW OIL SEAL WITH DRIFT. APPLY GREASE BETWEEN THE OIL SEAL LIPS.
- Special tool: Drift (398417700)
9. Press-fit companion flange with installer and weight.
10. INSTALL SELF-LOCKING NUT WITH WASHER.
- Torque (Drive pinion nut): 167-196 Nm (123-145 ft.lb)
11. ASSEMBLING DIFFERENTIAL CASE.
Install side gears and pinion mate gears, with their thrust washers and pinion mate shaft, into differential case.
Apply gear oil on both sides of the washer and on the side gear shaft before installing.
Insert the pinion mate shaft into the differential case by aligning the lock pin holes.
(1) Measure the clearance between differential case and the back of side gear.
(2) Adjust the clearance as specified by selecting side gear thrust washer.
Side gear back clearance: 0.1-0.2 mm (0.004-0.008 in)
(3) Check the condition of rotation after applying oil to the gear tooth surfaces and thrust surfaces.
(4) After driving in pinion shaft lock pin, stake the both sides of the hole to prevent pin from falling off.
(5) Install drive gear on differential case.
Tighten diagonally while tapping the bolt heads.
Torque (Drive gear bolt): 93-113 Nm (69-83 ft.lb)
Fig. 10 Measuring Side Bearing Width:
12. BEFORE INSTALLING SIDE BEARING, MEASURE THE BEARING WIDTH BY USING A DIAL GAUGE, WEIGHT AND GAUGE.
Set the dial gauge needle to zero, using a standard bearing or block of specified height in advance.
Standard bearing width: 20.00 mm (0.7874 in)
13. PRESS SIDE BEARING CONE ONTO DIFFERENTIAL CASE WITH DRIFT AND ADAPTER INCLUDED IN PULLER SET.
- Puller set - tool number (399527700).
14. ADJUSTING SIDE BEARING RETAINER SHIMS.
(1) The drive gear backlash and side bearing preload can be determined by the side bearing retainer shim thickness.
(2) When replacing differential case, differential carrier, side bearing and side bearing retainer, obtain the right and left retainer shim thickness from the following formulas.
Example Of Calculation (Part 1 Of 2):
Example Of Calculation (Part 2 Of 2):
T1 (Left) = (A + C + G1-D) x 0.01 + 0.76-E (mm)
T2 (Right) = (B + D + G2) x 0.01 + 0.76-F (mm)
T1 & T2: Thickness of left and right side bearing retainer shim (mm)
A & B: Number marked on differential carrier. Number marked on differential case.
C & D: Difference of width of left and right side bearing from standard width 20.0 mm, expressed in a unit of 0.01 mm. For example, if the bearing measured width is 19.89 mm, value of E or F is as follows. 20.00-19.89 = 0.11 (E or F)
G1 & G2: Number marked on side bearing retainer.
(3) Install the differential case assembly into differential carrier in the reverse order of disassembling.
Fig. 14 Side Bearing Retainer Position:
(4) Fit the selected shims and O-ring on side bearing retainer and install them on differential carrier with the arrow mark on the retainer directed as shown in Figure.
- Be careful that side bearing cup is not damaged by bearing roller.
(5) Tighten side bearing retainer bolts.
- On vehicle with LSD, apply a coat of Three Bond 1215 (P/N 004403007 to threads.
Torque (Side bearing retainer): 9-12 Nm (78-104 in.lb)
Fig. 15 Measuring Backlash:
(6) Measure the drive gear-to-drive pinion backlash. If the reading is not within the specified range, correct by decreasing the shim thickness on one side and increasing the shim thickness on the other side the same amount. Total shim thickness must be the same to maintain proper preload.
Backlash: 0.10-0.20 mm (0.0039-0.0079 in)
(7) At the same time, measure the turning resistance of drive pinion. Compared with the resistance when differential case is not installed, if the increase of the resistance is not within the specified range, readjust side bearing retainer shims.
Turning resistance increase: 0.1-0.6 Nm (0.9-5.2 inch lbs)
(8) Recheck drive gear-to-pinion backlash after readjusting shims.
Fig. 16 Measuring Runout:
(9) Check the drive gear runout on its back surface, and make sure pinion and drive gear rotate smoothly.
Limit of runout: 0.05 mm (0.0020 in)
15. CHECKING AND ADJUSTING TOOTH CONTACT OF DRIVE GEAR.
(1) Paint evenly both sides of three or four teeth on drive gear with red lead. Check the contact pattern after rotating drive gear several revolutions back and forth until definite contact pattern develops on drive gear.
(2) When the contact pattern is incorrect, readjust according to the instructions given in "Tooth contact pattern".
- Be sure to wipe off red lead completely upon completion of adjustment.
(3) After completing the above adjustment, install oil seal in side bearing retainer.
a. Use drift (398487700) to press the oil seal into position.
b. Apply chassis grease between the oil seal lips.
(4) Install rear cover.
Torque (Rear cover bolt): 19-25 Nm (14-19 ft.lb)