Part 2
REPLACEMENT OF DRIVE PINION SHAFT COMPONENTS1. REPLACE BEARING OF COUNTER DRIVEN GEAR
a. Using SST, press out the bearing.
SST 09950 - 00020
b. Using SST, press in a new bearing.
SST 09350 - 32013 (09351 - 32090)
2. REPLACE BEARING AND OUTER RACE OF DRIVE PINION SHAFT
a. Using SST, press out the bearing.
SST 09950 - 00020
b. Using SST, press in a new bearing.
SST 09350 - 32013 (09351 - 32100)
c. Using SST, drive out the outer race from the bearing cage.
SST 09350 - 32013 (09308 - 10010)
NOTE: Use SST without the bolt.
d. Using SST, press a new outer race into the bearing cage.
SST 09350 - 32013 (09351 - 32111, 09351 - 32130)
3. REPLACE OIL SEAL OF CAGE
a. Using SST, press out the two oil seals together.
SST 09350 - 32013 (09351 - 32090)
b. Using SST, press in a new oil seal, facing the lip downward.
SST 09350 - 32013 (09351 - 32090)
Oil seal press in depth (from flat end): 9.5 mm (0.374 in.)
c. Measure the oil seal press in depth.
Oil seal press in depth: 4 mm (0.16 in.)
d. With the oil seal lip facing upward, use SST to press in a new oil seal until its end is flush with the surface of the cage.
SST 09350 - 32013 (09351 - 32090)
e. Coat the oil seal lip with MP grease.
ADJUSTMENT OF DIFFERENTIAL SIDE BEARING PRELOAD
1. PLACE OUTER RACE AND ADJUSTING SHIM ONTO RH SIDE BEARING
Use the adjusting shim which was removed or one 2.40 mm (0.0945 in.) thick.
2. PLACE DIFFERENTIAL CASE INTO CASE
Be sure to install the adjusting shim into place.
3. INSTALL LH BEARING RETAINER
a. Do not install the O-ring yet.
b. Do not coat the bolt threads with sealer yet.
c. Temporarily tighten the bolts evenly and gradually while turning the ring gear.
4. INSTALL RH SIDE BEARING CAP
Tighten the bolts evenly and gradually while turning the ring gear.
Torque: 730 kg.cm (53 ft.lb, 72 N.m)
5. TIGHTEN LH BEARING RETAINER
Torque: 195 kg.cm (14 ft.lb, 19 N.m)
6. ADJUST SIDE BEARING PRELOAD
Using SST and torque meter, measure the preload of the side bearing.
SST 09564 - 32011
NOTE: Install SST on the pinion shaft.
Preload (at starting):
New bearing 10 - 16 kg.cm (8.7 - 13.9 in.lb, 1.0 - 1.6 N.m)
Reused bearing 5 - 8 kg.cm (4.3 - 6.9 in.lb, 0.5 - 0.8 N.m)
If the preload is not within specification, remove the ring gear from the case.
Reselect the RH adjusting shim.
NOTE: The preload will change about 3 - 4 kg.cm (2.6 - 3.5 in.lb, 0.3 - 0.4 N.m) with each shim thickness.
7. REMOVE DIFFERENTIAL CASE AND COMPONENT PARTS
If the preload is adjusted within specification, remove the bearing retainer, differential case, RH side bearing and shim.
ASSEMBLY AND ADJUSTMENT OF DRIVE PINION SHAFT
1. INSTALL NEW O-RING ONTO BEARING CAGE
2. PLACE BEARING CAGE ONTO DRIVE PINION SHAFT
Be careful not to damage the oil seal with the splines.
3. INSTALL GOVERNOR DRIVE GEAR (A140L)
4. INSTALL DRIVE PINION SHAFT INTO CASE
Slightly tap the cage into the case until the groove with the bore can seen.
NOTE: Drive in the bearing cage until the surface of the bearing cage passes through the groove with the bore.
5. INSTALL SNAP RING INTO CASE
a. Using SST, install the snap ring into the groove.
SST 09350 - 32013 (09351 - 32050)
b. Slightly tap the bearing cage to fit the snap ring into the groove.
6. INSTALL ROTOR SENSOR (A140E)
Install the rotor sensor, facing the magnet outward.
7. INSTALL OIL SLINGER
Install the oil slinger, facing the lip outward.
8. INSTALL OUTER RACE
Using SST, drive the outer race into the case.
SST 09350 - 32013 (09351 - 32100, 09351 - 32140)
9. INSTALL NEW SPACER
Always use new spacer.
Install the spacer with the small end first.
10. INSTALL COUNTER DRIVEN GEAR ONTO SHAFT
a. Place a bar at the drive pinion side and position the other end of the bar against a vise or such.
b. Drive the gear onto the shaft until the nut can be installed on the threads of the shaft.
CAUTION: Be careful not to damage to the transmission case.
11. ADJUST DRIVE PINION PRELOAD
a. Coat the threads and surface of the nut with MP grease.
b. Using SST to hold the gear, tighten the nut.
Torque: 1.750 kg.cm (127 ft.lb, 172 N.m)
SST 09350 - 32013 (09351 - 32031) and 09330 - 00021
c. Turn the gear counterclockwise and clockwise several times.
d. Using a torque meter, measure the preload of the drive pinion.
Preload (at starting):
New bearing 10 - 16 kg.cm (8.7 - 13.9 in.lb, 1.0 - 1.6 N.m)
Reused bearing 5 - 8 kg.cm (4.3 - 6.9 in.lb, 0.5 - 0.8 N.m)
- If preload is greater than specification, replace the bearing spacer.
- If preload is less than specification, retighten the nut 130 kg.cm (9 ft.lb, 13 N.m) at a time until the specified preload is reached.
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure.
Do not back off the nut to reduce the preload.
Maximum torque: 2,950 kg.cm (213 ft.lb. 289 N.m)
e. If the preload is adjusted within specification, note the preload.
INSTALLATION OF DIFFERENTIAL
1. PLACE OUTER RACE AND SELECTED ADJUSTING SHIM ONTO RH SIDE BEARING
2. PLACE DIFFERENTIAL CASE INTO CASE
Be sure to install the adjusting shim into place.
3. INSTALL LH BEARING RETAINER
a. Install a new O-ring.
b. Position the retainer by tapping it while holding the differential case center with the retainer.
c. Clean the threads of the bolts and case with white gasoline.
d. Coat the threads of the bolts with sealer.
Sealer: Part No.08833-00070. THREE BOND 1324 or equivalent
e. Temporarily tighten the bolts evenly and gradually while turning the ring gear.
4. INSTALL RH SIDE BEARING CAP
Tighten the bolts evenly and gradually while turning the ring gear.
Torque: 730 kg.cm (53 ft.lb, 72 N.m)
5. TIGHTEN LH BEARING RETAINER
Torque: 195 kg.cm (14 ft.lb, 19 N.m)
6. MEASURE TOTAL PRELOAD
Using a torque meter, measure the total preload of the drive pinion shaft.
Total preload (at starting):
Add drive pinion preload
New bearing 2.9 - 4.0 kg.cm (2.5 - 3.5 in.lb, 0.3 - 0.4 N.m)
Reused bearing 1.5 - 2.0 kg.cm (1.3 - 1.7 in.lb, 0.1 - 0.2 N.m)
If the preload is not within specification, redisassemble and readjust.
7. STAKE COUNTER DRIVEN GEAR NUT
8. INSTALL DRIVE PINION CAP
9. INSTALL CARRIER COVER
a. Clean the threads of the bolts and case with white gasoline.
b. Coat the threads of the bolts with sealer.
Sealer: Part No. 08833-00070. THREE BOND 1324 or equivalent
c. Install the carrier cover over the gasket.
Torque: 250 kg.cm (18 ft.lb, 25 N.m)
POST ASSEMBLY
1. INSTALL MANUAL SHAFT AND LEVER
2. INSTALL PARKING LOCK PAWL
3. INSTALL PARKING LOCK ROD AND BRACKET
4. INSTALL NEW OVERDRIVE CLUTCH APPLY GASKET AND NEW OVERDRIVE BRAKE GASKET
Coat the new gaskets with petroleum jelly, and install them onto the case.
5. INSTALL OVERDRIVE UNIT
a. Install the intermediate shaft into the overdrive case.
b. Place the overdrive unit over a new gasket. Be sure to install the intermediate shaft into the case.
NOTE: Do not damage the bushing and oil seal ring.
c. Turn the counter driven gear with a screw driver to install the overdrive unit. Tighten the bolts.
Torque: 250 kg.cm (18 ft.lb, 25 N.m)
6. INSTALL VALVE BODY
7. INSTALL SPEED SENSOR OR GOVERNOR BODYZ
8. INSTALL OIL PAN
9. INSTALL SPEEDOMETER DRIVEN GEAR
10. INSTALL NEUTRAL START SWITCH
INSTALLATION OF TRANSAXLE