Reassembly

Reassembly
Judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc. after disassembly, prepare replacing parts and proceed to reassembly according to procedures as described.

CAUTION:
^ Drive bevel gear and pinion must be replaced as a set when either replacement becomes necessary.
^ When replacing taper roller bearing, replace as inner race and outer race assembly.

Differential Carrier





For press-fitting drive bevel pinion bearing outer races, use special tools as shown in the figure.
Special tool
(A): 09924-74510
(B): 09926-68310
(C): 09913-75510

Differential Case





1. After applying differential oil to differential gear (4), pinions (5), pinion shafts (6), thrust washer (2) and spring washer (1), install them in differential right case (3). For correct installing direction of thrust washer (2) and spring washer (1), refer to the figure.





2. When installing pinion shaft No. 2 (2) (shorter) into differential case and pinion, insert its "a" side into pinion joint (1).

NOTE: "a" is longer than "b". ("a" > "b")





3. Check differential pinion gear (1) for smooth rotation.





4. In the same manner as described in Step 1, install thrust washer (2), spring washer (1) and differential gear (4).





5. Install differential left case (1) and then tighten screws to specified torque.
"A": Cement 99000-32110
Tightening torque
Differential case screw (a): 9 Nm (0.9 kgf-m, 6.5 ft. lbs.)
6. Clean and degrease mating surface of drive bevel gear (hypoid gear) (1).





7. Apply thread lock cement to hatched part of drive bevel gear (1) as shown in the figure.
"A": Cement 99000-32110





8. Put drive bevel gear (3) on differential case (1) and fasten them with bolts (2) by tightening them to specified torque. Use thread lock cement for bolts (2).

CAUTION: Use of any other bolts than that specified is prohibited.

"A": Cement 99000-32110
Tightening torque
Bevel gear bolts (a): 105 Nm (10.5 kgf-m, 76.0 ft. lbs.)





9. Install special tool to differential case assembly and check that preload is within specification. If preload exceeds specified value, check if foreign matter is caught or gear is damaged.
Special tool
(B): 09928-06510
Side gear preload
Max. 2.5 Nm (0.25 kgf-m, 1.8 ft. lbs.)

Differential Side Bearing





1. Press-fit side bearing (1)with special tool and press.
Special tool
(A): 09944-66020





2. Hold bearing press-fitted in Step 1 with holder and press-fit side bearing on the other side.

NOTE: Be sure to use bearing holder for the purpose of protecting lower bearing.

Special tool
(A): 09944-66020
(B): 09951-1 6060

Drive Bevel Pinion





To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion differential carrier and mounting dummy.
Special tool
(A): 09900-20606
(B): 09926-78320
(C): 09922-75222
(D): 09922-76570
(E): 09951-46010
(F): 09926-78311-002





1. Install special tools with bearings and universal joint flange (2) to differential carrier (1).

NOTE: This installation requires no spacer or oil seal.

Special tool
(E): 09951 -46010
(F): 09926-78311-002





2. Tighten flange nut (1) so that specified bearing preload is obtained.

NOTE:
^ Before taking measurement with spring balance (2) or torque wrench (3), check for rotation by hand and apply small amount of differential oil to bearings.
^ On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds.

Special tool
(C): 09922-75222
(F): 09926-78311-002
Pinion bearing preload 0.9 - 1.7 Nm (9.0 - 17.0 kgf-cm, 7.8 - 14.7 inch lbs.)
Spring measure reading with special tool 18 N - 34 N (1.8 - 3.4 kgf, 4.0 - 7.5 lbs.)





3. Set dial gauge to mounting dummy and make 0 (zero) adjustment on surface plate (1).

NOTE:
^ When setting dial gauge to mounting dummy, tighten screw (2) 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
(A): 09900-20606
(B): 09926-78320





4. Place zero-adjusted mounting dummy and dial gauge set on pinion mounting 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
(A): 09900-20606
(B): 09926-78311
(D): 09922-76570
(F): 09926-78311-002
5. Obtain adjusting shim thickness by using measured value by dial gauge in previous step. Necessary shim thickness "e" = Dial gauge measured value "c"





6. Select adjusting shim(s) (2) closest to calculated value from among the following available sizes and put it in place and then press-fit rear bearing (1).
Calculated valve "f": Closest value to "e" (refer to Step 5).)
Special tool
(G): 09925-18011
(H): 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)





7. With new pinion spacer (3) inserted as shown in the figure, install front bearing (5) to differential carrier (4).

NOTE:
^ Make sure to use new spacer for reinstallation.
^ Apply differential oil to bearings.





8. 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.
"A": Grease 99000-25010
Special tool (1): 09951-18210





9. While tightening flange nut gradually with 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.
^ On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds.
^ Be sure to tighten gradually and carefully till specified starting torque is obtained. Turning back overtightened flange nuts should be avoided.

Pinion bearing preload 0.9 - 1.7 Nm (9.0 - 17.0 kgf-cm, 7.8 - 14.7 inch lbs.)
Spring measure reading with special tool 16 - 30 N (1.6 - 3.0 kgf, 3.5 - 6.6 lbs.)
Special tool
(C): 09922-76560
(a): 09922-66021

Assembling Unit
1. Place bearing outer races on their respective bearings. Used left and right outer races are not interchangeable.
2. Install case assembly in carrier.





3. Install side bearing adjusters on their respective carrier, making sure adjuster are threaded properly.
4. Align match marks (1) on cap and carrier. Screw in 2 side bearing cap bolts 2 or 3 turns and press down bearing cap by hand.

NOTE: If bearing cap does not fit tightly on carrier, side bearing adjuster is not threaded properly. Reinstall adjuster.





5. Tighten cap bolts (provisional torque).
Tightening torque
Bearing cap bolt (Provisional torque)(a): 15 Nm (1.5 kgf-m, 11.0 ft. lbs.)





6. Tighten both bearing adjusters (2)so as to obtain specified gear backlash and at the same time, obtain preload of side bearing.

NOTE:
^ Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
^ As a practical measure the following would be recommended to obtain specified backlash and side bearing preload at the same time.
- Obtain specified backlash by turning both adjusters inward lightly.
- Tighten both adjusters further by one notch at a time.
^ Measure at least 4 points on drive bevel gear periphery.

Standard backlash 0.13 - 0.18 mm (0.005 - 0.007 inch)
Special tool
(A): 09930-40120
(B): 09930-40113
(C): 09900-20701





7. Measure preload of pinion bearing with spring balance (1) or torque wrench (2) and check composite preload of pinion bearing and side bearing.

NOTE:
^ Before taking measurement with spring balance (1)or torque wrench (2), check for smooth rotation by hand.
^ On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds.

Composite preload of pinion bearing and side bearing 1.1 - 2.0 Nm (11.0 - 20.0 kgf-cm, 9.5 - 17.4 inch lbs.)
Spring measure reading with special tool 19.5 - 35.5 N (1.95 - 3.55 kgf, 4.30 - 7.83 lbs.)
Special tool (D): 09922-76560





8. Torque bearing cap bolts (2) to specification and install bearing lock plates.
Tightening torque
Lock plate bolt (b): 12 Nm (1.2 kgf-m, 9.0 ft. lbs.)
Bearing cap bolt (c): 85 Nm (8.5 kgf-m, 61.5 ft. lbs.)











9. As final step, check gear tooth contact as follows.
a. After cleaning 10 drive bevel gear teeth, paint them with gear marking compound evenly by using brush (1) or sponge etc.
b. Turn gear to bring its painted part in mesh with drive bevel pinion and turn it back and forth by hand to repeat their contact.
c. Bring painted part up and check contact pattern. If contact pattern is not normal, readjust or replace as necessary according to instruction in the table.

NOTE: Be careful not to turn drive bevel gear more than one full revolution, for it will hinder accurate check.





10. Upon completion of gear tooth contact check in Step 9, caulk flange nut (2) with caulking tool (1) and hammer.