Part 2
Rear Differential Reassembly (continued)For H27 engine model
Special Tool
(C): 09922-75222
(F): 09926-78311-002
Pinion bearing preload
0.9 - 1.7 Nm (9.0 - 17.0 kg-cm, 7.8 - 14.7 inch lbs.)
Spring measure reading with special tool
18 N - 34 N (1.8 - 3.4 kg, 4.0 - 7.5 lb)
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): 09900-20607
(B): 09926-78311 (for H25 engine model)
(B): 09926-78320 (for H27 engine model)
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.
For H25 engine model
Special Tool
(A): 09900-20607
(B): 09926-78311
(D): 09951-16070
(E): 09922-77250
For H27 engine model
Special Tool
(A): 09900-20607
(B): 09926-78311
(D): 09922-76570
(F): 09926-78311-002
5. Obtain adjusting shim thickness by the following equation.
For H25 engine model
"102" in equation below is "a"+"b" of mounting dummy
For H27 engine model
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).
For H25 engine model
Calculated value "g" (For H25 engine model)
Closest value to "f" (refer to Step 5))
Calculated value "f" (For H27 engine model)
"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
(I): 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 kg-cm, 7.8 - 14.7 inch lbs.)
Spring measure reading with special tool
For H25 engine model: 18 - 34 N (1.8 - 3.4 kg, 4.0 - 7.5 lb)
For H27 engine model: 16 - 30 N (1.6 - 3.0 kg, 3.5 - 6.6 lb)
Special Tool
(C): 09922-75222 (for H25 engine model)
(C): 09922-76560 (for H27 engine model)
(J): 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 kg-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. For H25 engine model
Measure preload of pinion with spring balance (1) or torque wrench (2) and check composite preload of pinion bearing and side bearing.
NOTE:
^ Standard preload is shown in graph below, which should be read as follows.
Example:
When preload of bevel pinion is 26 N (2.6 kg, 5.73 lb), acceptable composite preload of both pinion bearings and side bearings should be between 2.8 and 3.2 kg / 6.17 and 7.05 lb.
Special Tool
(D): 09922-75222
^ Bearing preload can be checked roughly by using flange holder as shown in figure. In this measurement, holder arm itself will work as balance weight and torque will be replaced with angle. However, flange should be rotated very slowly with hand support so as not to allow over revolution due to inertia.
^ Repeat side bearing adjustment until gear backlash and composite bearing preload are compatible within specification, if failed to obtain specified measurements first.
Special Tool
(E): 09922-66021
8. For H27 engine model
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 kg-cm, 9.5 - 17.4 inch lbs.)
Spring measure reading with special tool
19.5 - 35.5 N (1.95 - 3.55 kg, 4.30 - 7.83 lb)
Special Tool
(D): 09922-76560
9. Torque bearing cap bolts (2) to specification and install bearing lock plates.
Tightening torque
Lock plate bolt b: 12 Nm (1.2 kg-m, 9.0 ft. lbs.)
Bearing cap bolt c: 85 Nm (8.5 kg-m, 61.5 ft. lbs.)
10. 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, referring to the following table. 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.
11. Upon completion of gear tooth contact check in Step 10), caulk flange nut (2) with caulking tool (1) and hammer.