Drive Bevel Pinion Shim Adjustment
Drive Bevel Pinion Shim AdjustmentDescription
To mesh bevel pinion and gear correctly, it is prerequired to install bevel pinion to differential carrier properly by using adjusting shim as described on following steps. Shown in this figure are relative positions of bevel pinion, differential carrier and mounting dummy.
Special Tool
(A): 09900-20606
(B): 09922-77280
(C): 09922-75222
Adjustment
1. Install bevel pinion dummy with front and rear bearings into differential carrier and then tighten 36 mm nut (Spare parts No.09159-28002 (1) lightly by hand.
Special Tool (B): 09922-77280
2. Install companion flange (4) to bevel pinion dummy.
3. Install special tool to companion flange (4) by using 4 flange bolts (2).
Special Tool (C): 09922-75222
4. Tighten 36 mm nut (1) while turning dummy about 50 rpm so that specified bearing preload is obtained.
NOTE:
^ This installation requires no spacer or oil seal.
^ Before taking measurement with special tool, apply thin coat of differential oil to bearings and turn bevel pinion dummy 15 revolutions or more to ensure its good fitting.
Pinion bearing preload (Pinion dummy rotational torque) 5.0 - 13.0 kgf-cm (4.4 - 11.2 inch lbs.)
Rotational force with special tool and spring balance 1.0 - 2.6 kg (2.2 - 5.7 lb)
5. Set dial gauge to bevel pinion mounting dummy and make 0 (zero) adjustment on surface plate (1) by screw (2).
Special Tool
(A): 09900-20606
(B): 09922-77280
6. 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.
Special Tool
(A): 09900-20606
(B): 09922-77280
7. Necessary adjusting shim thickness is the same valve as measured value by dial gauge.
Necessary shim thickness "e" = Dial gauge measured value "c"
8. Select adjusting shim (2) closest to obtained value from among following available sizes and put it in place and then press-fit rear bearing (1) to bevel pinion (3).
Available shim thickness
0.30, 0.87, 0.84, 0.81, 0.78, 0.75, 0.72, 0.69, 0.66, 0.63 and 0.60 mm (0.012, 0.034, 0.033, 0.032, 0.031, 0.029, 0.028, 0.027, 0.026, 0.025 and 0.024 inch)
Special Tool (D): 09925-18011
9. Using special tool and plastic hammer, drive oil seal into front case (1) till it becomes flush with front case end. Then apply grease to oil seal lip.
: Grease 99000-25010
Special Tool (E): 09913-85210
10. With new pinion spacer (2) inserted as shown in figure, install front bearing (4) to differential carrier (3).
Apply differential oil to front and rear bearings.
11. Install washer (5) to bevel pinion (1).
12. After applying sealant to mating surface of front case (6), install it to differential carrier (3).
"A": Sealant 99000-31110
Tightening torque
Front case bolts 23 Nm (2.3 kgf-cm, 17.0 ft. lbs.)
13. Install companion flange (2) to bevel pinion and tightening bevel pinion nut gradually with special tool and power wrench (1) to specified torque while turning bevel pinion. Set bearing preload of bevel pinion to specification.
NOTE:
^ Before taking measurement with spring balance, check for smooth rotation with turning bevel pinion 15 revolutions or more by hand.
^ Be sure to tighten gradually and carefully till specified pinion bearing preload is obtained. Turning back overtightened flange nuts should be avoided.
^ Measure pinion bearing preload while turning bevel pinion about 50 rpm.
Special Tool
(E): 09922-75222
(F): 09930-40113
Tightening torque
Bevel pinion nut 100 - 300 Nm (10.0 - 30.0 kgf-cm, 72.5 - 217.0 ft. lbs.) (Reference)
Bevel pinion bearing preload (Bevel pinion rotational torque) 5 - 13 Nm (0.5 - 1.3 kgf-cm, 4.4 - 11.2 ft. lbs.)
Rotational force with special tool 1 - 2.6 Nm (0.1 - 0.26 kgf-cm, 2.2 - 5.7 ft. lbs.)