Assembly
ASSEMBLYNOTE:
^ Assemble in the reverse order of disassembly.
^ 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 RH and LH bearing races.
^ Use a new O-ring and gasket.
^ Replace the oil seal with a new part at every disassembly.
^ Apply grease to the oil seal lip.
^ Be careful not to mix up the differential oil seal RH and LH.
1) Adjusting preload for front and rear bearings
NOTE: Adjust the bearing preload between front and rear bearings with collar and washer. Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted.
1) Install the rear bearing race (rear) into differential carrier with ST1 and ST2.
ST1 398477701 HANDLE
ST2 398477703 DRIFT 2
2) Install the rear bearing race (front) into differential carrier with ST1 and ST2.
ST1 398477701 HANDLE
ST2 398477702 DRIFT
3) Insert the ST1 into carrier with the pinion height adjusting washer and rear bearing cone fitted onto it.
NOTE:
^ If tooth contact is normal in the inspection before disassembling, verify that the washer is not deformed, and then re-use the used washer.
^ Use new rear bearing cone.
4) Install the preload adjusting collar and washer, front bearing cone, ST2, companion flange, and washer and self-locking nut.
ST1 398507702 DUMMY SHAFT
ST2 398507703 DUMMY COLLAR
5) Turn ST1 by hand to seat the bearing, and measure the initial load and initial torque with a spring scale or a torque wrench while tightening the self-locking nut. Select the preload adjusting washer and collar so that the specified preload is obtained when nut is tightened to the specified torque.
NOTE:
^ Use a new self-locking nut.
^ Be careful not to give excessive preload.
^ When tightening the self-locking nut, lock ST1 with ST2 as shown in the figure.
ST1 398507702 DUMMY SHAFT
ST2 398507704 BLOCK
Tightening torque: 181.5 N-m (18.5 kgf-m, 134.0 ft-lb)
Initial load: 17.7 - 38.8 N (1.8 - 4.0 kgf, 4.0 - 8.7 lb)
Initial torque: 0.67 - 1.47 N-m (0.07 - 0.15 kgf-m, 0.49 - 1.08 ft-lb)
2) Adjusting drive pinion height
Adjust the drive pinion height with washer installed between the rear bearing cone and the back of pinion gear.
1) Attach ST2.
ST1 398507702 DUMMY SHAFT
ST2 398507701 DIFFERENTIAL CARRIER GAUGE
ST3 398507703 DUMMY COLLAR
2) Measure the clearance N between the end of ST2 and the end surface of ST1 by using a thickness gauge.
NOTE: Make sure there is no clearance between the case and ST2.
ST1 398507702 DUMMY SHAFT
ST2 398507701 DIFFERENTIAL CARRIER 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.
T = To + N - (H x 0.01) - 0.20 mm (0.0079 in)
NOTE: Use copies of this page.
(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.
3) Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST.
ST 398177700 INSTALLER
4) Insert the drive pinion into the differential carrier, and install the selected bearing preload adjusting collar and washer.
5) Press-fit the front bearing cone into case with ST1, ST2 and ST3.
ST1 398507703 DUMMY COLLAR
ST2 399780104 WEIGHT
ST3 899580100 INSTALLER
6) Insert the collar, then press-fit the pilot bearing with ST1 and ST2.
ST1 399780104 WEIGHT
ST2 899580100 INSTALLER
7) Fit a new oil seal with ST.
NOTE:
^ Press-fit until the oil seal end comes 1 mm (0.04 in) inward from end of carrier.
^ Apply grease to the oil seal lips.
ST 498447120 INSTALLER
8) Press-fit the companion flange with ST1 and ST2.
NOTE: Be careful not to damage the bearing.
ST1 899874100 INSTALLER
ST2 399780104 WEIGHT
9) Apply seal material on the drive pinion shaft thread and new self-locking nut seat.
Seal material: THREE BOND 1324 (Part No. 004403042)
10) Attach a new self-locking nut and tighten using the ST.
ST 498427200 FLANGE WRENCH
Tightening torque: 181.5 N-m (18.5 kgf-m, 134.0 ft-lb)
11) Measure the initial torque or the initial load.
Initial load: 17.7 - 38.8 N (1.8 - 4.0 kgf, 4.0 - 8.7 lb)
Initial torque: 0.67 - 1.47 N-m (0.07 - 0.15 kgf-m, 0.49 - 1.08 ft-lb)
12) Assembling differential case
Install the side gears and pinion mate gears, with their thrust washers and pinion mate shaft, into the differential case. (Model without LSD)
NOTE:
^ 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 side gear backlash.
Side gear backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
2) Adjust the side gear backlash as specified by selecting side gear thrust washer.
3) Check the condition of rotation after applying oil to the gear tooth surfaces and thrust washer surfaces.
4) After inserting the pinion shaft lock pin into differential case, stake the both sides of the hole to prevent pin from falling off.
13) Install the hypoid driven gear to the differential case.
NOTE: Before installing bolts, apply seal material to bolt threads.
Seal material: THREE BOND 1324 (Part No. 004403042) or equivalent
NOTE: Tighten diagonally while gently tapping the bolt heads.
Tightening torque: 103 N-m (10.5 kgf-m, 76.0 ft-lb)
14) Press the side bearing into differential case using ST.
ST 398487700 DRIFT
15) Press the side bearing race into the side bearing retainer using the ST.
ST 398417700 DRIFT PUNCH
16) Adjusting the side bearing retainer shims
1) The hypoid driven gear backlash and the side bearing preload can be adjusted by the side bearing retainer shim thickness.
2) Install the differential case assembly into differential carrier in the reverse order of disassembly.
3) Install the side bearing retainer shims to retainers RH and LH from which they were installed.
NOTE: Replace the broken or corroded side retainer shim and O-ring with new parts of same thickness.
4) Align the arrow mark on differential carrier with the mark on side retainer during installation.
NOTE:
^ Replace the O-ring with a new part.
^ Be careful that the bearing roller does not damage the side bearing race.
5) Tighten the side bearing retainer bolts.
Tightening torque: 10.5 N-m (1.1 kgf-m, 7.7 ft-lb)
6) Measure the backlash between hypoid driven gear and drive pinion. Set the magnet base on differential carrier. Align the contact point of dial gauge with the tooth surface of hypoid driven gear, and move the hypoid driven gear while securing the drive pinion. Read the value indicated on dial gauge. If the backlash is not within the range of specifications, adjust the side bearing retainer shim using the following procedures.
^ When backlash exceeds 0.2 mm (0.008 in): Reduce the hypoid driven gear back surface shim thickness and increase the hypoid driven gear tooth surface side shim thickness. -When backlash is less than 0.1 mm (0.004 in): Increase the hypoid driven gear back surface shim thickness and reduce the tooth surface side shim thickness.
Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
7) At the same time, measure the total preload of the drive pinion. Compared with the resistance when differential case is not installed, if the total preload is not within specification, adjust the thickness of side bearing retainer shims, increasing/reducing both shims by an even amount at a time.
Total preload: 20.7 - 54.4 N (2.1 - 5.5 kgf, 4.7- 12.21b)
17) Recheck the backlash between hypoid driven gear and pinion.
Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
18) Check the hypoid driven gear runout on its back surface, and make sure that pinion and hypoid driven gear rotates smoothly.
If the hypoid driven gear runout on its rear face exceeds the limit, check for any foreign objects between hypoid driven gear and differential case, and for any deformation of the case or gear.
Hypoid driven gear runout on its back surface: 0.05 mm (0.002 in) or less
19) Checking and adjusting the 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 several revolutions back and forth until a definite contact pattern appears on the hypoid driven gear.
2) When the contact pattern is not correct, readjust.
NOTE: Be sure to wipe off the red lead completely after the adjustment is completed.
^ Correct tooth contact
Check item: Tooth contact pattern is slightly shifted toward toe side under no-load rotation. (When driving, it moves towards the heel side.)
^ Face contact
Check item: Backlash is too large.
Contact pattern
Corrective action: Increase the thickness of pinion height adjusting washer according to the procedure for bringing the drive pinion closer to the hypoid driven gear.
^ Flank contact
Check item: Backlash is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for moving the drive pinion away from hypoid driven gear.
^ Toe contact (inside contact)
Check item: Contact area is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for moving the drive pinion away from hypoid driven gear.
^ Heel contact (outside end contact)
Check item: Contact area is too small.
Contact pattern
Corrective action: Increase the thickness of pinion height adjusting washer according to the procedure for bringing the drive pinion close to the hypoid driven gear.
20) If proper tooth contact is not obtained, once again adjust the drive pinion height by changing the RH and LH side bearing retainer shims and the hypoid gear backlash.
1) Drive pinion height
ST1 398507702 DUMMY SHAFT
ST2 398507701 DIFFERENTIAL CARRIER GAUGE
T = To + N - (H x 0.01) - 0.20 (mm)
Place:
T = Thickness of the pinion height adjusting washer (mm)
To = Thickness of the washer temporarily assembled (mm)
N = Clearance measured by thickness gauge (mm)
H = Figure marked on drive pinion head
2) Hypoid gear backlash
Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
21) Remove the RH and LH side bearing retainer.
22) Install the O-rings and the side bearing retainer shims to both the left and right side bearing retainers.
23) Install the oil seals to the left and right side bearing retainers.
24) Align the arrow mark on differential carrier with the mark on side retainer during installation.
25) Apply liquid gasket to the bolts indicated by arrow marks, and install the side bearing retainer.
Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent
Tightening torque: 10.5 N-m (1.1 kgf-m, 7.7 ft-lb)
26) Install the new gasket and rear cover and tighten the bolts to specified torque.
Tightening torque: 29.5 N-m (3.0 kgf-m, 21.8 ft-lb)
27) Install the new air breather cap.
28) Install the oil drain plug and filler plug.
Tightening torque: 49 N-m (5.0 kgf-m, 36.2 ft-lb)
INSPECTION
Wash all the disassembled parts clean, and examine them for wear, damage and other defects. Repair or replace the defective parts as necessary.
1) Hypoid driven gear and drive pinion
^ If there is evidently an abnormal tooth contact, find out the cause and adjust until the teeth contact correctly. Replace the gear if there is an excessive worn or an incapable adjustment.
^ If crack, cutout or seizure is found, replace the parts as a set. Slight damage of some teeth can be corrected by oil stone or the like.
2) Bearing
Replace if seizure, peeling, wear, rust, dragging during rotation, noise or other defect is evident.
3) Oil seal
Replace if deformed or damaged, and at every disassembling.
4) Differential carrier
Replace if the bearing bores are worn or damaged.
5) Differential case
Replace if its sliding surfaces are worn or cracked.
6) Companion flange
Replace if the oil seal lip contacting surface has flaws.
SIDE GEAR BACKLASH
Using a dial gauge, check the backlash of side gear. (Model without LSD)
Side gear backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
If the side gear backlash is not within the specification, select the side gear thrust washer and adjust the side gear backlash as specified.
HYPOID DRIVEN GEAR BACKLASH
Using a dial gauge, check the backlash of hypoid driven gear.
Hypoid driven gear backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
If the hypoid driven gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.
HYPOID DRIVEN GEAR RUNOUT ON ITS BACK SURFACE
Using a dial gauge, check the hypoid driven gear runout on its back surface.
Hypoid driven gear rear face runout limit: 0.05 mm (0.002 in) or less
If the hypoid driven gear runout exceeds 0.05 mm (0.002 in), replace the hypoid driven gear.
TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION
Inspect the tooth contact between hypoid driven gear and drive pinion.
TOTAL PRELOAD
Using a spring scale, check the total preload.
Total preload: 20.7 - 54.5N (2.1 - 5.5 kgf, 4.7 - 12.2 lb)
If the total preload is not within the specification, adjust the side bearing retainer shims.
ADJUSTMENT
SIDE GEAR BACKLASH
Adjust the side gear backlash.
HYPOID DRIVEN GEAR BACKLASH
Adjust the hypoid driven gear backlash.
TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION
Adjust the tooth contact between hypoid driven gear and drive pinion gear.
TOTAL PRELOAD
Adjust the side bearing shim.
TOTAL PRELOAD
Using a spring scale, check the total preload.
Total preload: 20.7 - 54.4 N (2.1 - 5.5 kgf, 4.7- 12.2 lb)
If the total preload is not within the specification, adjust the side bearing retainer shims.
COMPANION FLANGE
1) If rust or dirt is attached to the companion flange, remove them.
2) Set a dial gauge at a companion flange surface (mating surface of propeller shaft and companion flange), and then measure the companion flange runout.
Limit of runout: 0.08 mm (0.003 in)
3) Set the gauge inside of the companion flange, and measure the runout.
Limit of runout: 0.08 mm (0.003 in)
4) If either runout exceeds the limit, move the phase of companion flange and drive pinion 90° each, and find the point where the runout is within the limit.
5) If the runout exceeds the limit after changing the phase, replace the companion flange and recheck the runout.
6) If the runout exceeds the limit after replacing the companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.