Converter Case Section

1. Check the appearance of each component and clean.
- Make sure each part is free of harmful cuts, damage and other faults.





2. Install the washer and snap ring to the speedometer shaft, and set the oil seal. Then force-fit the shaft to the converter case.





3. Install the speedometer driven gear to the speedometer shaft, and secure with a snap ring.
4. Install the vehicle speed sensor 2.
a. Apply grease to the tip of the sensor key on its sensor side so that the key will not drop when assembling.
b. Fit the sensor key tip correctly in the key groove at the tip of the speedometer shaft in the converter case.





5. Force-fit the oil seal to the converter case.
6. Install the differential assembly to the case, paying special attention not to damage the speedometer gears (drive and driven) and the inside of the case (particularly, the differential side retainer contact surface).
7. Install the circlip to the axle shaft, insert the shaft into the differential assembly, and tap it into position with a plastic hammer.
Thrust play: Approx. 0.3-0.5 mm (0.012-0.020 in)
a. If no play is felt, check whether the shaft is fully inserted. If shaft insertion is correct, replace the axle shaft.
b. Be sure to use a new circlip.

8. Wrap vinyl tape around the splined portion of the axle shaft.
9. Install the oil seal and outer race (taper roller bearing) to the differential side retainer. Then screw in the retainer after coating the threads with oil.
a. Pay attention not to damage the oil seal lips.
b. Do not confuse the RH and LH oil seals.
c. Keep the O-ring removed from the retainer.

10. Using the HANDLE (499787000), screw in the retainer until light contact is felt.
- Screw in the RH side slightly deeper than the LH side.

11. Hypoid gear backlash adjustment and tooth contact check





(1) Assemble the drive pinion assembly to the oil pump housing
a. Be careful not to bend the shims.
b. Be careful not to force the pinion against the housing bore.





(2) Tighten four bolts to secure the roller bearing.
Tightening torque: 36-42 Nm (27-31 ft.lb)

(3) Install the oil pump housing assembly to the converter case, and secure evenly by tightening four bolts.
Tightening torque: 30-36 Nm (22-27 ft.lb)

a. Thoroughly remove the liquid gasket from the case mating surface beforehand.
b. Use an old gasket or an aluminum washer so as not to damage the mating surface of the housing.





(4) Rotate the drive pinion several times.
(5) Tighten the LH retainer until contact is felt while rotating the shaft. Then loosen the RH retainer. Keep tightening the LH retainer and loosening the RH retainer until the pinion shaft can no longer be turned. This is the "zero" state.
(6) After the "zero" state is established, back off the LH retainer 3 notches and secure it with the locking tab. Then back off the RH retainer and retighten until it stops. Repeat this procedure several times. Tighten the RH retainer 1-3/4 notches further. This sets the preload. Finally, secure the retainer with its locking tab.
- Turning the retainer by one tooth changes the backlash about 0.05 mm (0.0020 in).





(7) Turn the drive pinion several rotations and check to see if the backlash is within the standard value.
Backlash: 0.13-0.18 mm (0.0051-0.0071 in)

- After confirming that the backlash is correct, check the tooth contact.





(8) Apply red lead evenly to the surfaces of three or four teeth of the crown gear. Rotate the drive pinion in the forward and reverse directions several times. Then remove the oil pump housing, and check the tooth contact pattern. If tooth contact is improper, readjust the backlash or shim thickness.

(9) If tooth contact is correct, mark the retainer position and loosen it. After fitting the O-ring, screw in the retainer to the marked position. Then tighten the lock plate to the specified torque.
Tightening torque: 23-26 Nm (17-20 ft.lb)





12. Install the seal pipe to the converter case. Be sure to use a new seal pipe.
13. Install two oil seals to the oil seal retainer with INSTALLER (499247300).
a. Pay attention to the orientation of the oil seals.
b. Be careful not to damage the seal lips. If any damage is found, replace with a new one.





14. Attach the O-ring to the oil seal retainer with Vaseline. Install the seal to the oil





15. Install the oil seal retainer taking care not to damage the oil seal lips. Then secure with three bolts. Make sure the O-ring is fitted correctly in position.
Tightening torque: 6-8 Nm (52-70 in.lb)





16. Apply Vaseline to the groove on the oil pump cover, and install two (R) seal rings and two (H) seal rings.
a. Fit the seal ring after compressing, and rub Vaseline into the seal ring to avoid expansion.
b. The "R" seal ring has a large diameter, while "H" has small diameter.

17. Install the rubber seal to the converter case. Be careful not to lose the rubber seal.