Part 1

REAR FINAL DRIVE ASSEMBLY


Disassembly and Assembly


COMPONENTS











ASSEMBLY INSPECTION AND ADJUSTMENT
- Before inspection and adjustment, drain gear oil.

Total Preload Torque
1. Secure final drive assembly onto an attachment.

Tool number A: KV38100800 (J-25604-01)

2. Remove side flanges.
3. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.





4. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
5. Measure total preload with the preload gauge.

Tool number A: ST3127S000 (J-25765-A)

Total preload torque: 2.84 - 3.75 Nm (0.29 - 0.38 kg-m, 26 - 33 in-lb)

NOTE:
Total preload torque = Pinion bearing preload torque + Side bearing preload torque
- If measured value is out of the specification, disassemble it to check and adjust each part. Adjust the pinion bearing preload and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bearing preload.

When the preload torque is large
On pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting washers by the same amount to each side. Refer to RFD-38, "Inspection and Adjustment". [1][2]Differential Assembly
When the preload is small
On pinion bearings: Tighten the drive pinion lock nut.
On side bearings: Use thicker side bearing adjusting washers by the same amount to each side. Refer to RFD-38, "Inspection and Adjustment". [1][2]Differential Assembly

Drive Gear Runout
1. Remove rear cover. Refer to "Differential Assembly".





2. Fit a dial indicator to the drive gear back face.
3. Rotate the drive gear to measure runout.

Runout limit: 0.05 mm (0.0020 in)

- If the runout is outside of the repair limit, check drive gear assembly condition; foreign material may be caught between drive gear and differential case, or differential case or drive gear may be deformed, etc.

CAUTION:
Replace drive gear and drive pinion gear as a set.

Tooth Contact
1. Remove rear cover. Refer to "Differential Assembly".





2. Apply red lead to drive gear.

CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 locations evenly spaced on drive gear.





3. Rotate drive gear back and forth several times, check drive pinion gear to drive gear tooth contact.

CAUTION:
Check tooth contact on drive side and reverse side.










4. If tooth contact is improperly adjusted, follow the procedure below to adjust the pinion height (dimension X).





- If the tooth contact is near the face (face contact), or near the heel
(heel contact), thicken pinion height adjusting washers to move drive pinion closer to drive gear. Inspection and Adjustment.





- If the tooth contact is near the flank (flank contact), or near the toe
(toe contact), thin pinion height adjusting washers to move drive pinion farther from drive gear. Inspection and Adjustment.

Backlash
1. Remove rear cover. Refer to "Differential Assembly".





2. Fit a dial indicator to the drive gear face to measure the backlash.

Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)

- If the backlash is outside of the specified value, change the thickness of side bearing adjusting washer.

When the backlash is large:
Make drive gear back side adjusting washer thicker, and drive gear tooth side adjusting washer thinner by the same amount. Refer to RFD-38, "Inspection and Adjustment". [1][2]Differential Assembly
When the backlash is small:
Make drive gear back side adjusting washer thinner, and drive gear tooth side adjusting washer thicker by the same amount. Refer to RFD-38, "Inspection and Adjustment". [1][2]Differential Assembly


CAUTION:
Never change the total amount of washers as it will change the bearing preload.

Companion Flange Runout





1. Fit a test indicator to the inner side of companion flange (socket diameter).
2. Rotate companion flange to check for runout.

Runout limit: 0.08 mm (0.0031 in)

3. If the runout value is outside the runout limit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90� step, and search for the position where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, possible cause will be an assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for these items and repair if necessary.
c. If the runout value is still outside of the limit after the check and repair, replace companion flange.

DISASSEMBLY

Differential Assembly
1. Drain gear oil, if necessary.
2. Remove side flange.
3. Remove rear cover mounting bolts.





4. Remove rear cover to insert the seal cutter between gear carrier and rear cover.

Tool number A: KV38100800 (J-25604-01)

CAUTION:
- Be careful not to damage the mating surface.
- Never insert flat-bladed screwdriver, this way damage the mating surface.





5. Using two 45 mm (1.77 in) spacers, mount carrier on the attachment.

Tool number A: KV10111100 (J-37228)





6. For proper reinstallation, paint matching marks on one side of the bearing cap.

CAUTION:
- For matching marks, use paint. Never damage bearing caps and gear carrier.
- Bearing caps are line-board during manufacture. The matching marks are used to reinstall them in their original positions.





7. Remove bearing caps.





8. Lift differential case assembly out with a suitable tool.





- Keep side bearing outer races together with inner race. Never mix them up.
Also, keep side bearing adjusting washers together with bearings.





9. Remove side bearing inner race.
To prevent damage to bearing, engage puller jaws in groove
( ).

Tool number
A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)

CAUTION:
- To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
- It is not necessary to remove side bearing inner race except it is replaced.





10. For proper reinstallation, paint matching marks on one differential case assembly.

CAUTION:
For matching marks, use paint. Never damage differential case and drive gear.
11. Remove drive gear mounting bolts.
12. Tap drive gear off differential case assembly with a soft hammer.

CAUTION:
Tap evenly all around to keep drive gear from bending.





13. Remove lock pin of pinion mate shaft with a punch from drive gear side.





14. Remove pinion mate shaft.





15. Turn pinion mate gear, then remove pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from differential case.

Drive Pinion Assembly
1. Remove differential assembly. Refer to "Differential Assembly".





2. Remove drive pinion lock nut with the flange wrench.





3. Put matching mark (B) on the end of drive pinion. The matching mark should be in line with the matching mark (A) on companion flange (1).

CAUTION:
For matching mark, use paint. Never damage companion flange and drive pinion.

NOTE:
The matching mark (A) on the final drive companion flange (1) indicates the maximum vertical runout position.
When replacing companion flange, matching mark is not necessary.





4. Remove companion flange using the suitable puller.





5. Press drive pinion assembly out of gear carrier.

CAUTION:
Never drop drive pinion assembly.
6. Remove front oil seal.
7. Remove side oil seal.
8. Remove pinion front bearing inner race.
9. Remove collapsible spacer.





10. Remove pinion rear bearing inner race and pinion height adjusting washer with the replacer (A) (commercial service tool).





11. Tap pinion front/rear bearing outer races uniformly a brass rod or equivalent to removed.

CAUTION:
Be careful not to damage gear carrier.

INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures below.






ADJUSTMENT AND SELECTION OF ADJUSTING WASHERS

Differential Side Gear Clearance
- Assemble the differential parts if they are disassembled. Refer to "Differential Assembly".





1. Place differential case straight up so that side gear to be measured comes upward.





2. Using feeler gauge, measure the clearance between side gear back and differential case at 3 different points, while rotating side gear. Average the 3 readings, and then measure the clearance of the other side as well.

Side gear back clearance specification: 0.2 mm (0.008 in) or less.
(Each gear should rotate smoothly without excessive resistance during differential motion.)

CAUTION:
To prevent side gear from tilting, insert feeler gauges with the same thickness from both sides.
3. If the back clearance is outside the specification, use a thicker/thinner side gear thrust washer to adjust. Inspection and Adjustment.

When the back clearance is large: Use a thicker thrust washer.
When the back clearance is small: Use a thinner thrust washer.

CAUTION:
Select a side gear thrust washer for right and left individually.

Side Bearing Preload
- Selecting carrier side bearing adjusting washers is required for successful completion of this procedure.





1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.
2. Place the differential case, with side bearings and bearing races installed, into gear carrier.





3. Insert left and right original side bearing adjusting washers in place between side bearings and gear carrier.





4. Install bearing caps in their correct locations and tighten bearing cap mounting bolts to the specified torque. Refer to "COMPONENTS".
5. Turn the carrier several times to seat the bearings.





6. Measure the turning torque of the carrier at the drive gear mounting bolts with a spring gauge (commercial service tool).

Specification:
34.2 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb) of pulling force at the drive gear bolt





7. If the turning torque is outside the specification, use a thicker/thinner side bearing adjusting washer to adjust. Inspection and Adjustment.

If the turning torque is less than the specified range:
Use a thicker thrust washer.
If the turning torque is greater than the specification:
Use a thinner thrust washer.

CAUTION:
Select a side bearing adjusting washer for right and left individually.
8. Record the total amount of washer thickness required for the correct carrier side bearing preload.

Pinion Gear Height





1. Make sure all parts are clean and that the bearings are well lubricated.
2. Assemble the pinion gear bearings into the differential shim selector tool.

Tool number: - (J-34309)





- Pinion front bearing; make sure the J-34309-3 pinion front bearing seat is secured tightly against the J-34309-2 gauge anvil. Then turn the pinion front bearing pilot, J-34309-5, to secure the bearing in its proper position.
- Pinion rear bearing; the pinion rear bearing pilot, J-34309-8, is used to center the pinion rear bearing only. The pinion rear bearing locking seat, J-34309-4, is used to lock the bearing to the assembly.
- Installation of J-34309-9 and J-34309-16; place a suitable 2.5 mm (0.098 in) thick plain washer between J-34309-9 and
J-34309-16. Both surfaces of J-34309-9 and J-34309-16 must be parallel with a clearance of 2.5 mm (0.098 in).





3. Install the pinion rear bearing inner race into gear carrier. Then place the pinion preload shim selector tool, J-34309-1, gauge screw assembly.





4. Assemble the pinion front bearing inner race and the J-34309-2 gauge anvil. Assemble them together with the J-34309-1 gauge screw in gear carrier. Make sure that the pinion height gauge plate, J-34309-16, will turn a full 360 degrees. Tighten the two sections together by hand.





5. Turn the assembly several times to seat the bearings.





6. Measure the turning torque at the end of the J-34309-2 gauge anvil using preload gauge.

Tool number: ST3127S000 (J-25765- A)
Turning torque specification: 1.0 - 1.3 Nm (0.11 - 0.13 kg-m, 9 - 11 in-lb)





7. Place the J-34309-11 "R200A" pinion height adapter onto the gauge plate and tighten it by hand.

CAUTION:
Make sure all machined surfaces are clean.





8. Position the side bearing discs, J-25269-4, and arbor firmly into the side bearing bores. Install the bearing caps and tighten bearing cap mounting bolts to the specified torque. Refer to "COMPONENTS".





9. Select the correct standard pinion height adjusting washer thickness. Select by using a standard gauge of 3 mm (0.12 in) and your J-34309-101 feeler gauge. Measure the distance between the J-34309-11 pinion height adapter including the standard gauge and the arbor.





10. Write down exact measurement (the value of feeler gauge).





11. Correct the pinion height washer size by referring to the "pinion head number".
There are two numbers painted on the drive pinion. The first one refers to the drive pinion and drive gear as a matched set. This number should be the same as the number on the drive gear. The second number is the "pinion head height number". It refers to the ideal pinion height from standard for quietest operation. Use the following chart to determine the correct pinion height washer.





12. Select the correct pinion height adjusting washer. Inspection and Adjustment.





13. Remove the J-34309 differential shim selector tool from the final drive housing. Then disassemble to retrieve the pinion bearings.