Adjustment

DIFFERENTIAL ASSEMBLY


Adjustment


TOTAL PRELOAD TORQUE
Before inspection and adjustment, drain gear oil.
1. Secure final drive assembly onto an attachment [SST: 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 (A) [SST:
ST3127S000 (J-25765-A)].

Standard
Total preload torque : Refer to "Preload Torque". Preload Torque

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. For selecting adjusting washer, refer to the latest parts information.
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. For selecting adjusting washer, refer to the latest parts information.


SIDE BEARING PRELOAD
Before inspection and adjustment, drain gear oil.
1. Remove rear cover. Disassembly.





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





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





5. Install bearing caps in their correct locations and tighten bearing cap mounting bolts.
6. Turn the carrier several times to seat the bearings.
7. Measure the turning torque of the carrier at the drive gear mounting bolts with a spring gauge [SST: --
(J-8129)].

Standard
Specification : Refer to "Preload Torque". Preload Torque





8. If the turning torque is outside the specification, use a thicker/thinner side bearing adjusting washer to adjust. For selecting adjusting washer, refer to the latest parts information.

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

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

DRIVE GEAR RUNOUT
1. Remove rear cover. Disassembly.





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

Limit
Drive gear runout : Refer to "Drive Gear Runout". Drive Gear Runout

- 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
Before inspection and adjustment, drain gear oil.
1. Remove rear cover. Disassembly.





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.
For selecting adjusting washer, refer to the latest parts information.





- 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.
For selecting adjusting washer, refer to the latest parts information.

BACKLASH
Before inspection and adjustment, drain gear oil.
1. Remove rear cover. Disassembly.





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

Standard
Backlash : Refer to "Backlash". Backlash

- 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. For selecting adjusting washer, refer to the latest parts information.
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. For selecting adjusting washer, refer to the latest parts information.

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