Assembly
ASSEMBLYSTI MODEL
1) Precautions for assembling
^ Assemble in the reverse order of disassembling.
^ Check and adjust each part during assembly.
^ Keep the shims and washers in order, so that they are not improperly installed.
^ Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed.
^ Apply gear oil when installing the bearings and thrust washers.
^ Be careful not to mix up the right and left hand races of the bearings.
^ Replace the oil seal with a new one at every disassembly. Apply chassis grease between the lips when installing the oil seal.
^ 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.
2) Press-fit the rear bearing race into differential carrier using ST.
ST 398417700 DRIFT
3) Press-fit the front bearing race into differential carrier using ST.
ST 398477702 DRIFT
4) Pinion height adjusting washer selection.
(1) Measure the thickness of inserted pinion height adjusting washer.
(2) Read the punch mark of installed drive pinion gear and new one.
NOTE:
If there is no punch mark, it means 0 (zero).
(3) Obtain the thickness of pinion height adjust shim to be inserted from the following formula, and replace the inserted shim with this one.
(Example of calculation)
T1 = 3.30, T2 = +2, T3 = -1 T = 3.30 + [(2 x 0.01) - (-1 x 0.01)1 = 3.33
Result: Thickness = 3.33 mm
Therefore use the washer 38336AA310.
5) Install the selected pinion height adjusting washer on drive pinion, and press-fit the rear bearing cone into position with ST.
ST 18674AA000 INSTALLER
6) Insert the drive pinion into differential carrier, install the previously selected bearing preload adjusting spacer and washer.
7) Insert the spacer, then press-fit the pilot bearing with STs.
ST1 399780104 WEIGHT
ST2 899580100 INSTALLER
ST3 398507703 DUMMY COLLER
ST4 498937110 HOLDER
8) Press-fit the companion flange with ST1, ST2 and ST3.
NOTE:
Be careful not to damage the bearing.
ST1 899874100 INSTALLER
ST2 399780104 WEIGHT
ST3 498937110 HOLDER
9) Apply Lock Tite to the bolt threads of drive pinion shaft, and the seating surface of new self-locking nut.
Lock Tite:
THREE BOND 1324 (Part No. 004403042)
10) Install the self-locking nut. Then tighten it with the ST.
ST 18633AA000 WRENCH COMPL
11) Rotate the drive pinion shaft more than ten times to accustom each taper roller bearing, and then measure the preload.
12) If bearing preload is out of specification, adjust to specification by selecting preload adjusting washer and spacer from the following table.
13) Hold the companion flange with ST and remove the self-locking nut.
ST 18633AA000 WRENCH COMPL
14) Extract the companion flange with a puller.
15) Fit a new oil seal with ST.
NOTE:
^ Press-fit until the end of oil seal is 1 mm (0.04 inch) inward from end of carrier.
^ Apply grease between the oil seal lips.
ST 498447120 INSTALLER
16) Press-fit the companion flange with ST1, ST2 and ST3.
ST1 899874100 INSTALLER
ST2 399780104 WEIGHT
ST3 498937110 HOLDER
NOTE:
Be careful not to damage the bearing.
17) Apply Lock Tite to the bolt threads of drive pinion shaft, and the seating surface of new self-locking nut.
Lock Tite:
THREE BOND 1324 (Part No. 004403042)
18) Install the self-locking nut. Then tighten it with the ST.
ST 18633AA000 WRENCH COMPL
19) Install the hypoid driven gear on differential case.
NOTE:
^ Before installing the bolts, apply Lock Tite to bolt threads.
^ Make sure that there is no clearance between differential case and driven gear.
Lock Tite:
THREE BOND 1324 (Part No. 004403042) or equivalent
NOTE:
Tighten diagonally while tapping the bolt heads.
20) Press-fit the side bearing onto differential case with ST.
ST 398487700 DRIFT
21) Assembling side bearing retainer.
(1) Press-fit the side bearing outer race with press and ST.
ST 398417700 DRIFT
(2) Install the oil seal.
22) Adjusting side bearing retainer shims
(1) The driven gear backlash and side bearing preload can be determined by the side bearing retainer shim thickness.
(2) Install the differential case assembly into differential carrier in the reverse order of disassembly.
NOTE:
Be careful not to hit the teeth against the case.
(3) Install the side bearing retainer shims to the right and left retainers from which they were removed.
NOTE:
Replace the broken or corroded side bearing retainer shim with a new one of same thickness.
(4) Align the arrow mark on differential carrier with the mark on side bearing retainer during installation.
NOTE:
Be careful that side bearing outer race is not damaged by bearing roller.
(5) Tighten the side bearing retainer bolts.
(6) Measure the hypoid driven gear-to-drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of hypoid driven gear, and move the hypoid driven gear while holding drive pinion still. Read the value indicated on dial gauge.
NOTE:
If the backlash exceeds 0.20 mm (0.008 inch), reduce the thickness of shim on the back face of hypoid driven gear and increase the thickness of shim on the tooth face of hypoid driven gear. If the backlash is less than 0.10 mm (0.004 inch), increase the thickness of shim on the back face of hypoid driven gear and reduce the thickness of shim on the tooth face of hypoid driven gear.
(7) At the same time, measure the total preload of drive pinion. Compared with the resistance when differential case is not installed, if the total preload is not within the specified range, readjust side bearing retainer shims, increasing/reducing by an even amount at a time.
Total preload.
27 - 54 N (2.8 - 5.50 kgf, 6.1 - 12.2 lbs.)
23) Re-check the hypoid driven gear-to-pinion backlash.
24) Check the hypoid driven gear runout on its back surface, and make sure that pinion and hypoid driven gear rotate smoothly.
25) Checking and adjusting tooth contact of hypoid driven gear
(1) Apply an even coat of red lead on both sides of three or four teeth on the hypoid driven gear. Check the contact pattern after rotating the hypoid driven gear several revolutions back and forth until a definite contact pattern appears on the hypoid driven gear.
(2) 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.
^ Correct tooth contact
Checking item: Tooth contact pattern is slightly shifted toward to toe side under no-load rotation. (When loaded, contact pattern moves toward heel)
^ Face contact
Checking item: Backlash is too large.
Contact pattern
Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring drive pinion close to hypoid driven gear.
^ Flank contact
Checking item: Backlash is too small.
Contact pattern
Corrective action: Reduce thickness of drive pinion height adjusting washer in order to move drive pinion away from hypoid driven gear.
^ Toe contact (Inside end contact)
Checking item: Contact area is small.
Contact pattern
Corrective action: Reduce thickness of drive pinion height adjusting washer in order to move drive pinion away from hypoid driven gear.
^ Heel contact (Outside end contact)
Checking item: Contact area is small.
Contact pattern
Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring drive pinion close to hypoid driven gear.
26) If proper tooth contact is not obtained, once again adjust the drive pinion height by changing RH and LH side bearing retainer shims and the hypoid gear backlash.
27) Remove the side bearing retainers on right and left side.
28) Install new O-rings to side bearing retainers on right and left side.
29) Align the arrow mark on differential carrier with the mark on side bearing retainer during installation.
30) Apply liquid gasket to the bolt with arrow mark, and install the side bearing retainer.
Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent
31) Install the new gasket, rear cover and stay ground and tighten the bolts to specified torque.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft. lbs.)
32) Install the new air breather cap.
33) Install the drain plug and rear differential oil temperature switch or oil temperature sensor.
