Adjustment

DRIVE PINION


AWD : Adjustment


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 [SST: -- (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, turns 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 [SST: ST3127S000 (J-25765-A)].






Standard
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 Exploded View.





9. Select the correct standard pinion height adjusting washer thickness. Select by using a standard gauge of 3 mm (0.12 in) and 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.
13. Remove the J-34309 differential shim selector tool from the final drive housing. Then disassemble to retrieve the pinion bearings.






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.





Limit
Companion flange runout : Refer to DLN-208, "Companion Flange Runout (AWD)". Companion Flange Runout





3. If the runout value is outside the runout limit, follow the procedure below to adjust.
Check for runout while changing the phase between companion flange and drive pinion by 90� step, and a.
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.