Assembly

DRIVE PINION


2WD : Assembly






1. Install front bearing outer race (1) and rear bearing outer race
(2) using drifts (A, B and D) and drift bar (C).

A : Drift [SST: ST30720000 (J-25405)]
B : Drift [SST: KV40105230 ( - )]
C : Drift bar [SST: ST30611000 (J-25742-1)]
D : Drift [SST: ST30613000 (J-25742-3)]


CAUTION:
- At first, using a hammer, tap bearing outer race until it becomes flat to gear carrier.
- Never reuse pinion front and rear bearing outer race.
2. Select drive pinion height adjusting washer. Adjustment.





3. Install selected drive pinion height adjusting washer (2) to drive pinion. Press pinion rear bearing inner race (1) to it, using drift
(A) [SST: ST30901000 (J-26010-01)].

CAUTION:
- Be careful of the direction of pinion height adjusting washer. (Assemble as shown in the figure.)
- Never reuse pinion rear bearing inner race.





4. Assemble collapsible spacer to drive pinion.

CAUTION:
Never reuse collapsible spacer.
5. Apply gear oil to pinion rear bearing, and assemble drive pinion into gear carrier.
6. Apply gear oil to pinion front bearing, and assemble pinion front bearing inner race to drive pinion assembly.

CAUTION:
Never reuse pinion front bearing inner race.





7. Using suitable spacer (A) (commercial service tool), press the pinion front bearing inner race to drive pinion as far as drive pinion nut can be tightened.





8. Using the drift (A) [SST: ST30720000 (J-25405)], install front oil seal as shown in figure.

CAUTION:
- Never reuse oil seal.
- When installing, never incline oil seal.
- Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
9. Install companion flange.

NOTE:





When reusing drive pinion, align the matching mark (B) of drive pinion with the matching mark (A) of companion flange, and then install companion flange (1).





10. Apply anti-corrosion oil to the thread and seat of drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion, using flange wrench (commercial service tool).

A : Preload gauge [SST: ST3127S000 (J-25765-A)]

CAUTION:
Never reuse drive pinion lock nut.
11. Adjust to the drive pinion lock nut tightening torque and pinion bearing preload torque, using preload gauge [SST: ST3127S000
(J-25765-A)].

Standard
Pinion bearing preload : Refer to "Preload Torque". Preload Torque

CAUTION:
- Adjust to the lower limit of the drive pinion lock nut tightening torque first.
- If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Never loosen drive pinion lock nut to adjust the preload torque.
- After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction,
and other malfunctions.
12. Install differential case assembly. Assembly.

CAUTION:
Never install rear cover at this timing.
13. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion flange runout. Adjustment and Adjustment.
Recheck above items. Readjust the above description, if necessary.
14. Check total preload torque. Adjustment.
15. Install rear cover. Assembly.