1. EXCEPT FOR 2.5 L TURBO KA, KC, EK, ER MODELS
NOTE:
• 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 gasket and O-ring.
• Replace the oil seal with a new part at every disassembly.
• Apply the differential gear oil to the lips when installing the oil seal.
• 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 spacer 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 into the differential carrier using ST1 and ST2.
| ST1 398477701 | HANDLE |
| ST2 398477703 | DRIFT 2 |
(2) Install the front bearing race to the differential carrier using 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 (drive pinion, hypoid driven gear) is normal in the inspection before disassembling, verify that the washer is not deformed, and then reuse the used washer.
• Use new rear bearing cone.
(4) Install the preload adjusting spacer and washer, front bearing cone, ST2, companion flange, washer and self-locking nut.
| ST1 398507702 | DUMMY SHAFT |
| ST2 398507703 | DUMMY COLLAR |
|
(A) |
Pinion height adjusting washer |
|
(B) |
Preload adjusting spacer |
|
(C) |
Preload adjusting washer |
(5) Turn the ST1 by hand to smooth the bearing, and tighten the self-locking nut while measuring the initial load or initial torque with a spring scale or torque wrench. Select the preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque.
NOTE:
• Use a new self-locking nut.
• Measure the preload in direction of tangent to the flange.
• 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, 133.9 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)
|
Preload adjusting washer |
Part No. |
Thickness mm (in) |
|
383705200 |
2.59 (0.1020) | |
|
383715200 |
2.57 (0.1012) | |
|
383725200 |
2.55 (0.1004) | |
|
383735200 |
2.53 (0.0996) | |
|
383745200 |
2.51 (0.0988) | |
|
383755200 |
2.49 (0.0980) | |
|
383765200 |
2.47 (0.0972) | |
|
383775200 |
2.45 (0.0965) | |
|
383785200 |
2.43 (0.0957) | |
|
383795200 |
2.41 (0.0949) | |
|
383805200 |
2.39 (0.0941) | |
|
383815200 |
2.37 (0.0933) | |
|
383825200 |
2.35 (0.0925) | |
|
383835200 |
2.33 (0.0917) | |
|
383845200 |
2.31 (0.0909) | |
|
Preload adjusting spacer |
Part No. |
Length mm (in) |
|
383695201 |
56.2 (2.213) | |
|
383695202 |
56.4 (2.220) | |
|
383695203 |
56.6 (2.228) | |
|
383695204 |
56.8 (2.236) | |
|
383695205 |
57.0 (2.244) | |
|
383695206 |
57.2 (2.252) |
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 the ST2.
NOTE:
At this time, install a provisionally selected or previously used pinion height adjusting washer. Measure and record the thickness.
| ST1 398507702 | DUMMY SHAFT |
| ST2 398507701 | DIFFERENTIAL CARRIER GAUGE |
| ST3 398507703 | DUMMY COLLAR |
|
(A) |
Pinion height adjusting washer |
(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 × 0.01) − 0.20 mm (0.0079 in)
NOTE:
Use copies of this page.
|
T |
Thickness of pinion height adjusting washer mm (in) | |
|
To |
Thickness of washer temporally inserted mm (in) | |
|
N |
Clearance of thickness gauge mm (in) | |
|
H |
Figure marked on drive pinion head | |
|
Memo: | ||
(Example of calculation)
To = 2.20 mm (0.0866 in) + 1.20 mm (0.0472 in) = 3.40 mm (0.1339 in)
N = 0.23 mm (0.0091 in)
H = +1
T = 3.40 mm (0.1339 in) + 0.23 mm (0.0091 in) − 0.01 mm (0.0004 in) − 0.20 mm (0.0079 in) = 3.42 mm (0.1346 in)
Result: Thickness = 3.42 mm (0.1346 in)
Therefore use washer 383605200.
|
Pinion height adjusting washer | |
|
Part No. |
Thickness mm (in) |
|
383495200 |
3.09 (0.1217) |
|
383505200 |
3.12 (0.1228) |
|
383515200 |
3.15 (0.1240) |
|
383525200 |
3.18 (0.1252) |
|
383535200 |
3.21 (0.1264) |
|
383545200 |
3.24 (0.1276) |
|
383555200 |
3.27 (0.1287) |
|
383565200 |
3.30 (0.1299) |
|
383575200 |
3.33 (0.1311) |
|
383585200 |
3.36 (0.1323) |
|
383595200 |
3.39 (0.1335) |
|
383605200 |
3.42 (0.1346) |
|
383615200 |
3.45 (0.1358) |
|
383625200 |
3.48 (0.1370) |
|
383635200 |
3.51 (0.1382) |
|
383645200 |
3.54 (0.1394) |
|
383655200 |
3.57 (0.1406) |
|
383665200 |
3.60 (0.1417) |
|
383675200 |
3.63 (0.1429) |
|
383685200 |
3.66 (0.1441) |
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 preselected bearing preload adjusting spacer and washer.
|
(A) |
Drive pinion |
|
(B) |
Bearing preload adjusting spacer |
|
(C) |
Bearing preload adjusting washer |
|
(D) |
Differential carrier |
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 spacer, 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 differential gear oil 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) or equivalent
10. Attach new self-locking nuts, and tighten with the ST.
| ST 498427200 | FLANGE WRENCH |
Tightening torque:
181.5 N·m (18.5 kgf-m, 133.9 ft-lb)
11. Assembling differential case
Install the side gears and pinion mate gears, with their thrust washers and pinion mate shaft, into the differential case.
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 backlash as specified by selecting side gear thrust washer.
|
Side gear thrust washer | |
|
Part No. |
Thickness mm (in) |
|
383445201 |
0.75 — 0.80 (0.0295 — 0.0315) |
|
383445202 |
0.80 — 0.85 (0.0315 — 0.0335) |
|
383445203 |
0.85 — 0.90 (0.0335 — 0.0354) |
(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.
12. Install the driven gear to differential case.
NOTE:
• Before installing bolts, apply a sealing material to bolt threads.
SEAL MATERIAL
THREE BOND 1324 (Part No. 004403042) or equivalent
• Make sure there is no clearance between the differential case and driven gear.
• Tighten opposing bolts in order.
Tightening torque:
103 N·m (10.5 kgf-m, 76.0 ft-lb)
13. Press the side bearing into differential case using ST.
| ST 398487700 | DRIFT |
14. Press the side bearing outer race into the side retainer using the ST.
| ST 398417700 | DRIFT |
15. Side retainer shim adjustment
(1) The driven gear backlash and side bearing preload can be adjusted by the side retainer shim thickness.
(2) Install the differential case assembly into differential carrier in the reverse order of disassembly.
NOTE:
Be careful so that the teeth do not hit against the case.
(3) Install the side retainer shims and O-ring to the same side retainers RH and LH to which they were originally installed.
NOTE:
• Replace the O-ring with a new part.
• Replace broken or corroded side retainer shims with a new part of the same thickness.
|
Side retainer shim | |
|
Part No. |
Thickness mm (in) |
|
383475201 |
0.20 (0.0079) |
|
383475202 |
0.25 (0.0098) |
|
383475203 |
0.30 (0.0118) |
|
383475204 |
0.40 (0.0157) |
|
383475205 |
0.50 (0.0197) |
(4) Align the arrow mark on differential carrier with the mark on side retainer during installation.
NOTE:
Be careful that side bearing outer race is not damaged by the bearing roller.
|
(A) |
Arrow mark |
(5) Tighten the side retainer bolt.
Tightening torque:
10.5 N·m (1.1 kgf-m, 7.7 ft-lb)
(6) Measure the hypoid driven gear to drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of the driven gear, and move the driven gear while holding the drive pinion still. Read the value indicated on dial gauge. If the backlash not within the standard range, adjust the side retainer shim according to the following method.
•When backlash is less than 0.1 mm (0.004 in):
Reduce the thickness of shim on the back side of the hypoid driven gear and increase the thickness of shims on the teeth side of the hypoid driven gear.
•When backlash exceeds 0.2 mm (0.008 in):
Increase the thickness of shim on the back side of the hypoid driven gear and reduce the thickness of shims on the teeth side of the hypoid driven gear.
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 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 — 12.2 lbf)
16. Recheck the hypoid driven gear to drive pinion backlash.
Backlash:
0.10 — 0.20 mm (0.004 — 0.008 in)
17. Check the runout on the back side of the hypoid driven gear, and make sure that the pinion and hypoid driven gears rotate smoothly.
If the runout on the back side of the hypoid driven gear exceeds the specification, check for any foreign material between the hypoid driven gear and differential case, and for any deformation of the case or gear.
Hypoid driven gear back surface runout:
0.05 mm (0.002 in)
18. Checking and adjusting the tooth contact of hypoid driven gear
(1) Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Check the contact pattern after rotating the hypoid driven gear 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 lead-free red dye 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.)
|
(A) |
Toe side |
|
(B) |
Heel side |
• Face contact
Check item: Backlash is too large.
Contact pattern
Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring drive pinion close to 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 bringing drive pinion away from hypoid driven gear.
• Toe contact (inside contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.
• Heel contact (outside end contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring the drive pinion closer to the hypoid driven gear.
19. If correct tooth contact is not obtained, once again adjust the drive pinion height by changing the RH and LH side retainer shims and the hypoid gear backlash.
(1) Drive pinion height
| ST1 398507702 | DUMMY SHAFT |
| ST2 398507701 | DIFFERENTIAL CARRIER GAUGE |
T = To + N − (H × 0.01) − 0.20 (mm)
Place:
T = Thickness of pinion height adjusting washer (mm)
To = Thickness of washer temporarily inserted (mm)
N = Clearance of 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)
20. Remove the RH and LH side retainers.
21. Install new O-rings to the side retainers on both sides.
22. Install the oil seal to the side retainer of both sides. 
23. Align the arrow mark on differential carrier with the mark on side retainer during installation.
|
(A) |
Arrow mark |
24. Apply liquid gasket to the bolt with arrow marks and install the side 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)
25. 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)
26. Install the air breather cap.
|
(A) |
Air breather cap |
|
(B) |
Rear cover |
27. Install the oil drain plug and filler plug.
Tightening torque:
49 N·m (5.0 kgf-m, 36.1 ft-lb)
2. 2.5 L TURBO KA, KC, EK, ER MODELS
1. Cautions for assembling:
• 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 the differential gear oil to the lips when installing the oil seal.
• Be careful not to mix up the differential oil seal RH and LH.
• Adjust the bearing preload between front and rear bearings with spacer and washer. Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted.
2. Using the ST, press-fit the rear bearing race to the differential carrier.
| ST 398417700 | DRIFT PUNCH |
3. Using the ST, press-fit the front bearing race to the differential carrier.
| ST 398477702 | DRIFT |
4. Selecting the pinion height adjusting washer
(1) Measure the thickness of the inserted pinion height adjusting washer.
(2) Read the stamp of the attached drive pinion gear and a new part.
NOTE:
When there is no stamp, it indicates 0 (zero).
(3) Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the installed washer with this one.
T = T1 + (T2 × 0.01 − T3 × 0.01)
|
T mm |
Thickness of the selected pinion height adjusting washer |
|
T1 mm |
Thickness of the inserted pinion height adjusting washer |
|
T2 mm |
Stamped number on the attached drive pinion gear |
|
T3 mm |
Stamped number on the new drive pinion gear |
(Example of calculation)
T1 = 3.30, T2 = +2, T3 = −1
T = 3.30 + {(2 × 0.01) − (−1 × 0.01)} = 3.33
Answer: Thickness = 3.33 mm
The washer to be used is 38336AA310.
|
Pinion height adjusting washer | |
|
Part No. |
Thickness mm (in) |
|
38336AA230 |
3.09 (0.1217) |
|
38336AA240 |
3.12 (0.1228) |
|
38336AA250 |
3.15 (0.1240) |
|
38336AA260 |
3.18 (0.1252) |
|
38336AA270 |
3.21 (0.1264) |
|
38336AA280 |
3.24 (0.1276) |
|
38336AA290 |
3.27 (0.1287) |
|
38336AA300 |
3.30 (0.1299) |
|
38336AA310 |
3.33 (0.1311) |
|
38336AA320 |
3.36 (0.1323) |
|
38336AA330 |
3.39 (0.1335) |
|
38336AA340 |
3.42 (0.1346) |
|
38336AA350 |
3.45 (0.1358) |
|
38336AA360 |
3.48 (0.1370) |
|
38336AA370 |
3.51 (0.1382) |
|
38336AA380 |
3.54 (0.1394) |
|
38336AA390 |
3.57 (0.1406) |
|
38336AA400 |
3.60 (0.1417) |
|
38336AA410 |
3.63 (0.1429) |
|
38336AA420 |
3.66 (0.1441) |
5. Attach the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST.
| ST 18674AA000 | INSTALLER |
6. Insert the drive pinion into the differential carrier, and install the originally attached bearing preload adjusting spacer and washer.
|
(A) |
Drive pinion |
|
(B) |
Bearing preload adjusting spacer |
|
(C) |
Bearing preload adjusting washer |
|
(D) |
Differential carrier |
7. Insert the spacer, then press-fit the pilot bearing using the ST.
| ST1 399780104 | WEIGHT |
| ST2 899580100 | INSTALLER |
| ST3 398507703 | DUMMY COLLAR |
| ST4 498937110 | HOLDER DRIVE PINION |
8. Press-fit the companion flange with ST1, ST2 and ST3.
NOTE:
Be careful not to damage the bearing.
| ST1 899874100 | INSTALLER |
| ST2 399780104 | WEIGHT |
| ST3 498937110 | HOLDER DRIVE PINION |
9. Install the self-lock nut. Tighten it using the ST.
| ST 498427200 | FLANGE WRENCH |
Tightening torque:
181.5 N·m (18.5 kgf-m, 133.9 ft-lb)
10. Turn the drive pinion shaft 10 turns or more to seat on each taper roller bearing properly, and measure the initial load or initial torque.
Initial load:
24.1 — 38.6 N (2.5 — 3.9 kgf, 5.4 — 8.7 lb)
Initial torque:
0.91 — 1.46 N·m (0.09 — 0.15 kgf-m, 0.67 — 1.08 ft-lb)
11. When the bearing preload is outside the specified range, select the preload adjusting washer and spacer from the following table in order to make it within the specified range.
|
Preload adjusting washer |
Part No. |
Thickness mm (in) |
|
383705200 |
2.59 (0.1020) | |
|
383715200 |
2.57 (0.1012) | |
|
383725200 |
2.55 (0.1004) | |
|
383735200 |
2.53 (0.0996) | |
|
383745200 |
2.51 (0.0988) | |
|
383755200 |
2.49 (0.0980) | |
|
383765200 |
2.47 (0.0972) | |
|
383775200 |
2.45 (0.0965) | |
|
383785200 |
2.43 (0.0957) | |
|
383795200 |
2.41 (0.0949) | |
|
383805200 |
2.39 (0.0941) | |
|
383815200 |
2.37 (0.0933) | |
|
383825200 |
2.35 (0.0925) | |
|
383835200 |
2.33 (0.0917) | |
|
383845200 |
2.31 (0.0909) | |
|
Preload adjusting spacer |
Part No. |
Length mm (in) |
|
31454AA130 |
52.2 (2.055) | |
|
31454AA140 |
52.4 (2.063) | |
|
31454AA150 |
52.6 (2.071) | |
|
31454AA160 |
52.8 (2.079) | |
|
31454AA170 |
53.0 (2.087) | |
|
31454AA180 |
53.2 (2.094) |
12. Remove the self-locking nut while holding the companion flange with ST.
| ST 498427200 | FLANGE WRENCH |
13. Extract the companion flange with a puller.
|
(A) |
Companion flange |
|
(B) |
Puller |
14. Install a new oil seal using ST.
NOTE:
• Press-fit until the oil seal end comes 1 mm (0.04 in) inward from end of carrier.
• Apply the differential gear oil to the oil seal lips.
| ST 498447120 | INSTALLER |
15. Press-fit the companion flange with ST1, ST2 and ST3.
| ST1 899874100 | INSTALLER |
| ST2 399780104 | WEIGHT |
| ST3 498937110 | HOLDER DRIVE PINION |
NOTE:
Be careful not to damage the bearing.
16. Install the self-lock nut. Tighten it using the ST.
| ST 498427200 | FLANGE WRENCH |
17. Check the initial torque and initial load.
Initial load:
24.1 — 38.6 N (2.5 — 3.9 kgf, 5.4 — 8.7 lb)
Initial torque:
0.91 — 1.46 N·m (0.09 — 0.15 kgf-m, 0.67 — 1.08 ft-lb)
18. Install the driven gear to differential case.
NOTE:
• Before installing bolts, apply a sealing material to bolt threads.
• Tighten opposing bolts in order.
SEAL MATERIAL
THREE BOND 1324 (Part No. 004403042) or equivalent
Tightening torque:
103 N·m (10.5 kgf-m, 76.0 ft-lb)
19. Press the side bearing into differential case using ST.
| ST 398487700 | DRIFT |
20. Assembling the side retainer
(1) Press-fit the side bearing outer race using the ST and press.
| ST 398417700 | DRIFT |
(2) Install the oil seal.
21. Side retainer shim adjustment
(1) The driven gear backlash and side bearing preload can be adjusted by the side retainer shim thickness.
(2) Install the differential case assembly into differential carrier in the reverse order of disassembly.
NOTE:
Be careful so that the teeth do not hit against the case.
(3) Install the side retainer shims and O-ring to the same side retainers RH and LH to which they were originally installed.
NOTE:
• Replace the O-ring with a new part.
• Replace broken or corroded side retainer shims with a new part of the same thickness.
|
Side retainer shim | |
|
Part No. |
Thickness mm (in) |
|
383475201 |
0.20 (0.0079) |
|
383475202 |
0.25 (0.0098) |
|
383475203 |
0.30 (0.0118) |
|
383475204 |
0.40 (0.0157) |
|
383475205 |
0.50 (0.0197) |
(4) Align the arrow mark on differential carrier with the mark on side retainer during installation.
NOTE:
Be careful that side bearing outer race is not damaged by the bearing roller.
|
(A) |
Arrow mark |
(5) Tighten the side retainer bolt.
Tightening torque:
10.5 N·m (1.1 kgf-m, 7.7 ft-lb)
(6) Measure the driven gear to drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of the driven gear, and move the driven gear while holding the drive pinion still. Read the value indicated on dial gauge. If the backlash is outside the standard range, adjust the side retainer shim by the following method.
• When backlash is less than 0.1 mm (0.004 in):
Reduce the thickness of shim on the back side of the hypoid driven gear and increase the thickness of shims on the teeth side of the hypoid driven gear.
• When backlash exceeds 0.2 mm (0.008 in):
Increase the thickness of shim on the back side of the hypoid driven gear and reduce the thickness of shims on the teeth side.
Backlash:
0.10 — 0.20 mm (0.004 — 0.008 in)
(7) At the same time, measure the total preload of the drive pinion. If the total preload is not within specification as compared to the resistance when the differential case is not installed, adjust the thickness of the side retainer shims by slightly increasing/reducing both shims by the same amount.
Total preload:
27.0 — 54.0 N (2.8 — 5.5 kgf, 6.1 — 12.2 lb)
22. Recheck the hypoid driven gear to drive pinion backlash.
Backlash:
0.10 — 0.20 mm (0.004 — 0.008 in)
23. Check the runout on the back side of the hypoid driven gear, and make sure that the pinion and hypoid driven gears rotate smoothly.
If the hypoid driven gear runout on its back surface exceeds the specification, check for any foreign objects between the hypoid driven gear and differential case, and for any deformation of the case or gear.
Hypoid driven gear back surface runout:
0.05 mm (0.002 in)
24. Checking and adjusting the tooth contact of hypoid driven gear
(1) Apply an even coat of lead-free red dye on both sides of three or four hypoid driven gear teeth. Check the contact pattern after rotating the driven gear several revolutions back and forth until a definite contact pattern appears on the driven gear.
(2) When the contact pattern is not correct, readjust.
NOTE:
Be sure to wipe off the lead-free red dye 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.)
|
(A) |
Toe side |
|
(B) |
Heel side |
• Face contact
Check item: Backlash is too large.
Contact pattern
Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring drive pinion close to 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 bringing drive pinion away from hypoid driven gear.
• Toe contact (inside contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.
• Heel contact (outside end contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring the drive pinion closer to the hypoid driven gear.
25. If correct tooth contact is not obtained, once again adjust the drive pinion height by changing the RH and LH side retainer shims and the hypoid gear backlash.
26. Install the oil seal to the side retainer of both sides.
27. Align the arrow mark on differential carrier with the mark on side retainer during installation.
|
(A) |
Arrow mark |
28. Apply liquid gasket to the bolts indicated by arrows, and tighten the side retainer bolt.
Liquid gasket:
THREE BOND 1105 (Part No. 004403010) or equivalent
Tightening torque:
10.5 N·m (1.1 kgf-m, 7.7 ft-lb)
29. Install the new gasket and rear cover, and tighten the bolts to specified torque.
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
30. Install the air breather cap.