Assembly
1. Precautions for assembling.a. Assemble in the reverse order of disassembling.
b. Check and adjust each part during assembly.
c. Keep the shims and washers in order, so that they are not misinstalled.
d. Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed.
e. Apply gear oil when installing the bearings and thrust washers.
f. Be careful not to mix up the right and left hand cups of the bearings.
g. Replace the oil seal with new one at every disassembly. Apply chassis grease between the lips when installing the oil seal.
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 are not affected by this adjustment. The adjustment must be carried out without oil seal inserted.
a. Press rear bearing race into differential carrier with Special Tool (ST1) and ST2.
ST1 398477701 HANDLE
ST2 398427703 DRIFT 2
b. Insert ST1 into case with pinion height adjusting washer and rear bearing cone fitted onto it.
CAUTION:
- Re-use the used washer if not deformed.
- Use a new rear bearing cone.
c. Then install preload adjusting spacer and washer, front bearing cone, ST2, companion flange, and washer and drive pinion nut.
ST1 398507702 DUMMY ASSY or equivalent.
ST2 398507703 DUMMY COLLAR or equivalent.
d. Turn ST1 with hand to make it seated, and tighten drive pinion nut while measuring the preload with spring balance. Select preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque with ST2.
CAUTION: Use a new lock nut.
NOTE:
- Be careful not to give excessive preload.
- When tightening the drive pinion nut, lock ST1 with ST2 as shown in the image.
ST1 398507704 BLOCK
ST2 398507702 DUMMY ASSY or equivalent.
ST3 498427200 FLANGE WRENCH or equivalent.
Tightening Torque: 181 +/- 15 Nm (134 +/- 11 ft. lbs.).
Front and rear bearing preload For new bearing: 17.7 +/- 25.5 N (4.0 +/- 5.7 lbs.). at companion flange bolt hole.
3. Adjusting drive pinion height. Adjust drive pinion height with shim installed between rear bearing cone and the back of pinion gear.
a. Install ST1, ST2 and ST3, as shown in the image, and apply the specified preload on the bearings. Adjusting preload for front and rear bearings
NOTE: At this time, install a pinion height adjusting shim which is temporarily selected or the same as that used before.
b. Measure the clearance N between the end of ST3 and the end surface of ST1 by using a thickness gauge.
ST1 398507702 DUMMY ASSY or equivalent.
ST2 398507703 DUMMY COLLAR or equivalent.
ST3 398507701 DIFFERENTIAL CARRIER GAUGE or equivalent.
NOTE: Make sure there is no clearance between the case and ST3.
c. Obtain the thickness of pinion height adjusting shim to be inserted from the following formula, and replace the temporarily installed shim with this one. T = To + N - (H x 0.01) - 0.20 (mm)
Where:
T = Thickness of pinion height adjusting shim (mm)
To = Thickness of shim 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 shim 383605200.
4. Install the selected pinion height adjusting shim on drive pinion, and press the rear bearing cone into position with ST.
398177700 INSTALLER or equivalent.
5. Insert drive pinion (1) into differential carrier (4), install the previously selected bearing preload adjusting spacer (2) and washer (3).
6. Press-fit front bearing cone into case with ST1, ST2 and ST3.
ST1 398507703 DUMMY COLLAR or equivalent.
ST2 399780104 WEIGHT or equivalent.
ST3 899580100 INSTALLER or equivalent.
7. Insert spacer, then press-fit pilot bearing with ST1 and ST2.
ST1 399780104 WEIGHT or equivalent.
ST2 899580100 INSTALLER or equivalent.
8. Fit a new oil seal with ST.
ST 498447120 OIL SEAL INSTALLER or equivalent.
NOTE:
- Press-fit until end of oil seal is 1 mm (0.04 inch) inward from end of carrier.
- Apply grease between the oil seal lips.
9. Press-fit companion flange with ST1 and ST2 until flange protrudes 0 to 5 mm (0 to 0.20 inch) beyond shaft.
ST1 899874100 INSTALLER or equivalent.
ST2 399780104 WEIGHT or equivalent.
CAUTION: Be careful not to damage bearing.
10. Install self-locking nut. Then tighten it with ST.
ST 498427200 FLANGE WRENCH or equivalent.
Tightening Torque: 181 +/- 15 Nm (134 +/- 11 ft. lbs.).
11. Install crown gear on differential case.
Tightening Torque: 103 +/- 10 Nm (76 +/- 7 ft. lbs.).
NOTE: Tighten diagonally while tapping the bolt heads.
12. Before installing side bearing, measure the bearing width by using a dial gauge, ST1 and ST2.
ST1 398227700 WEIGHT or equivalent.
ST2 398237700 GAUGE or equivalent.
Standard bearing width: 20.00 mm (0.7874 inch).
NOTE: Set the dial gauge needle to zero, using a standard bearing or block of specified height in advance.
13. Press side bearing cone onto differential case with ST1.
ST1 398487700 DRIFT or equivalent.
14. Adjusting side bearing retainer shims
a. The drive gear backlash and side bearing preload can be determined by the side bearing retainer shim thickness.
b. When replacing differential case, differential carrier, side bearing and side bearing retainer, obtain the right and left retainer shim thickness from the following formulas.
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
C & D : Number marked on differential case
E & F : 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
If a number is not marked, regard it as zero.
NOTE: Use several shims to obtain the calculated thickness.
c. Install the differential case assembly into differential carrier in the reverse order of disassembly.
Fig. 14 Side Bearing Retainer Position:
d. 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 image.
CAUTION: Be careful that side bearing cup is not damaged by bearing roller.
e. Tighten side bearing retainer bolts.
Tightening Torque: 10.3 +/- 1.5 Nm (7.6 +/- 1.1 ft. lbs.).
Fig. 15 Measuring Backlash:
f. Measure the crown gear-to-drive pinion backlash. Set magnet base on differential carrier. Align contact point of dial gauge with tooth face of crown gear, and move crown gear while holding drive pinion still. Read value indicated on dial gauge.
Backlash: 0.10 - 0.20 mm (0.0039 - 0.0079 inch).
g. 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.).
NOTE: If measured backlash is not within specified range, repeat steps (a) thru (g).
Fig. 15 Measuring Backlash:
15. Re-check crown gear-to-pinion backlash.
Backlash: 0.10 - 0.20 mm (0.0039 - 0.0079 inch).
Fig. 16 Measuring Runout:
16. Check the crown gear runout on its back surface, and make sure pinion and crown gear rotate smoothly.
Limit of runout: 0.05 mm (0.0020 inch).
17. Checking and adjusting tooth contact of crown gear
a. Apply an even coat of red lead on both sides of three or four teeth on the crown gear. Check the contact pattern after rotating crown gear several revolutions back and forth until a definite contact pattern appears on the crown gear.
b. When the contact pattern is incorrect, readjust according to the instructions given in "TOOTH CONTACT PATTERN".
NOTE: Be sure to wipe off red lead completely after adjustment is completed.
18. If proper tooth contact is not obtained, once again adjust the drive pinion height and the differential side bearing preload (mentioned above) and the hypoid gear backlash.
19. Install rear cover and tighten bolts to specified torque.
Tightening Torque: 29 +/- 5 Nm (21.7 +/- 3.6 ft. lbs.).