Drive Bevel Pinion
DRIVE BEVEL PINION
To engage bevel pinion and gear correctly, it is pre-required to install bevel pinion to differential carrier properly by using adjusting shim as described on the following. Shown in the figure are relative positions of bevel pinion, differential carrier and mounting dummy.
Special tool
(A): 09900-20606
(B): 09926-78311
(C): 09922-75222
1. Install bevel pinion dummy with bearings into differential carrier and tighten flange nut (1) so that specified bearing preload is obtained.
NOTE:
^ This installation requires universal joint flange not equipped with groove on flange periphery.
^ This installation requires no spacer or oil seal.
^ Before taking measurement with spring balance (2) or torque wrench (3), check for rotation by hand and apply small amount of oil to bearings.
Special tool
(A): 09922-75222
(B): 09926-78311
Pinion bearing preload (a) 9.0 - 17.0 kg-cm (7.8 - 14.7 inch lbs.)
Spring measure reading 1.8 - 3.4 kg (4.0 - 7.5 lbs.)
2. Set dial gauge to bevel pinion mounting dummy and make 0 (zero) adjustment on surface plate.
NOTE:
^ When setting dial gauge to mounting dummy, tighten screw lightly. Be careful not to overtighten it, which will cause damage to dial gauge.
^ With dial gauge set, turn dummy back and force by hand a couple of times and attain accurate 0 (zero) adjustment.
^ It is desirable that short pointer indicates beyond 2 mm when long one is at 0 (zero).
Special tool
(C) 09926-78311
(D) 09900-20606
3. Place zero-adjusted mounting dummy and dial gauge set on pinion dummy and take measurement between zero position and extended dial gauge measuring tip.
NOTE:
^ Repeat turning back and force of dummy and measure distance as far as top surface of pinion dummy accurately.
^ When dial gauge measuring tip extends from 0 (zero) position, pointer turns counterclockwise.
^ Measured value may exceed 1 mm. Therefore, it is also necessary to know reading of short pointer.
Special tool
(C): 09926-78311
(D): 09900-20606
4. Obtain adjusting shim thickness by using measured value by dial gauge (which represents "c" in the first figure of "DRIVE BEVEL PINION") in the following equation.
94 in equation is "a" + "b" of mounting dummy (special tool) as shown in the first figure of "DRIVE BEVEL PINION".
5. Select adjusting shim(s) (2) closest to calculated value from among the following available sizes and put it in place and then press-fit front bearing (1).
Special tool
(E): 09925-18011
(F): 09927-66010
Available shim thickness 1.12, 1.15, 1.18, 1.21, 1.24, 1.27, 1.30 and 0.3 mm (0.044, 0.045, 0.046, 0.047, 0.048, 0.049, 0.050 and 0.012 inch)
6. With new pinion spacer (3) inserted as shown in the figure, install rear bearing (5) to differential carrier (4).
NOTE:
^ Make sure to use new spacer for reinstallation.
^ Apply oil to bearings.
7. Using special tool and plastic hammer drive oil seal (2) into differential carrier (1) till it becomes flush with carrier end. Then apply grease "A" to oil seal lip.
Special tool (G) 09951-18210
"A" Grease 99000-25010
8. While tightening flange nut gradually with flange holder (special tool) and power wrench (4 - 10 magnification) (1), set preload of pinion to specification.
NOTE:
^ Before taking measurement with spring balance (3) or torque wrench (4), check for smooth rotation by hand.
^ Bearing preload can be measured roughly by pinion rotating angle which is due to arm weight of flange holder installed in flange.
Refer to following page for further information.
^ Be sure to tighten gradually and carefully till specified starting torque is obtained. Turning back overtightened flange nuts should be avoided.
Pinion bearing preload: 9.0 - 17.0 kg-cm (7.8 - 14.7 inch lbs.)
Spring measure reading 1.8 - 3.4 kg (4.0 - 7.5 lb)
Special tool
(A): 09922-75222
(H): 09922-66020