Rear Differential
REAR DIFFERENTIAL
COMPONENTS
DISASSEMBLY
1. SIDE BEARING NUT
Using the special tool (09521-43001), remove the side bearing nut.
NOTE: Keep the right and left side bearing nuts separate so that they are not mixed during reassembly.
2. REMOVAL OF THE DIFFERENTIAL CASE ASSEMBLY
CAUTION:
^ Remove the differential case assembly slowly and carefully.
^ Be careful so that the side bearing outer race is not dropped.
^ Keep the right and left side bearing outer races separate so that they are not mixed during reassembly.
3. REMOVAL OF THE SIDE BEARING INNER RACES
Fit the nut on top of the differential case, and then use the special tool to remove the side bearing inner race.
NOTE: Attach the prongs of the special tool (09517-43001) to the inner race of the side bearing through the notched section in the differential case.
4. REMOVAL OF DRIVE GEAR
a. Make the matchmarks to the differential case and the drive gear.
b. Loosen the drive gear attaching bolts in diagonal sequence to remove the drive gear.
5. REMOVAL THE LOCK NUT
6. REMOVAL OF DRIVE PINION
a. Make the matchmarks on the drive pinion and companion flange.
CAUTION: Matchmarks should not be made on the contact surfaces of the companion flange and the propeller shaft.
b. Drive out the drive pinion together with the drive pinion spacer and drive pinion front shims.
7. REMOVAL OF DRIVE PINION REAR BEARING INNER RACE
8. REMOVAL OF OIL SEAL/DRIVE PINION FRONT BEARING INNER RACE/DRIVE PINION FRONT BEARING OUTER RACE
9. REMOVAL OF DRIVE PINION REAR BEARING OUTER RACE
INSPECTION
1. Check the companion flange for wear or damage.
2. Check the bearings for wear or discoloration.
3. Check the gear carrier for cracks.
4. Check the drive pinion and drive gear for wear or cracks.
5. Check the side gears, pinion gears and pinion shaft for wear or damage.
6. Check the side gear spline for wear or damage.
7. Check the length of the distance piece.
Standard length: 54.80 - 58.09 mm (2.16 - 2.21 inch)
REASSEMBLY
1. Install the drive pinion rear bearing outer race and drive pinion front bearing outer race using the special tools (09500-11000, 09500-21000, 09532-31200B and 09532-32000).
CAUTION: Eve careful not to press in the outer race when it is inclined.
2. ADJUSTMENT OF PINION HEIGHT
Adjustment the drive pinion height by the following procedure.
1. For assembly of pinion, use drive pinion model(OK993 270 A01), pinion height adjustment gauge body(OK993 270 A09) and gauge block (ht. 28 mm (1.102 inch)).
2. Assemble spacer and inner bearing inner race to pinion model and fix it with O-ring.
NOTE:
^ Use spacer disassembled.
3. Install pinion model assembly to carrier.
4. Assemble outer bearing, companion flange washer, and lock nut.
NOTE:
^ Use washer and lock nut disassembled.
5. Tighten lock nut.
NOTE:
^ Tighten to the extent the companion flange can be screwed by hand.
6. Put pinion height adjusting gauge body at right angle and adjust it to 0.
7. Put pinion height adjusting gauge body and gauge block to the upper side of pinion model.
8. Dial gauge needle should be placed at the lowest part of side bearing.
9. Measure minimum positions of both sides (LH, RH).
10. Add both values and divide it by 2.
11. If the value of the above step 10 is not within specification, use new spacer adding the values to current spacer.
Standard clearance: -0.025 - 0.025 mm (-0.001 - 0.001 inch)
3. Adjustment of drive pinion preload.
1. Install spacer.
2. Push inner bearing in using SST.
NOTE:
^ Keep pressuring until the sudden increase of necessary power.
^ Place the spacer for adjusting pinion height, ensuring exact direction of installation.
3. Install distance piece.
4. Push outer bearing in using SST.
5. Install drive pinion assembly.
6. Install companion flange and tighten lock nut.
Tightening torque: 127 - 284 Nm (13 - 29 kg-m, 94 - 210 ft. lbs.)
NOTE:
^ Do not install oil seal.
7. Turn companion flange by hand so that bearing be put at the right place.
8. Measure preload of drive pinion. If the result is not within specification, use new distance piece and measure again.
Preload: 127 - 176 Nm(13 - 18 kg-cm, 94 - 130 ft. lbs.)
9. Remove the lock nut and then install the oil seal.
10. Install the companion flange and tighten lock nut.
Tightening torque: 127 - 284 Nm (13 - 29 kg-m, 94 - 210 ft. lbs.)
ADJUSTMENT OF DIFFERENTIAL GEAR BACKLASH
Adjust the differential gear backlash according to the following procedures:
1. Assemble the side gears, side gear spacers, pinion gears, and pinion washers into the differential case.
2. Temporarily, install the pinion shaft.
NOTE: Do not install the lock pin yet.
3. Insert a wedge in the side gear and measure the differential gear backlash with a dial indicator on the pinion gear.
NOTE: Measure both pinion gears separately.
Standard value: 0 - 0.1 mm (0 - 0.0039 inch)
Limit: 0.2 mm (0.008 inch)
4. If the differential gear backlash exceeds the limit, adjust the backlash by installing thicker side gear thrust spacers.
5. Measure the differential gear backlash once again, and confirm that it is within the limit.
NOTE:
^ After adjustment, check that the backlash is within the limit and the differential gear rotates smoothly.
^ When adjustment is impossible, replace the side gear and the pinion gear as a set.
6. Installation of the drive gear
a. Clean the drive gear attaching bolts.
b. Remove the adhesive on the threaded holes of the drive gear with a tap (M12 x 1.5), and then clean the threaded holes with compressed air.
c. Apply the specified adhesive to the threaded holes of the drive gear.
Specified adhesive: LOCTITE #262 or equivalent
d. Install the drive gear in the differential case with the matchmarks properly aligned. Tighten the bolts to the specified torque (11 - 15 kg-m) in a diagonal sequence.
7. Press-fit the side bearing inner race
8. Align the matchmark on the gear carrier and the bearing cap, and then tighten the bearing cap.
9. ADJUSTMENT OF FINAL DRIVE GEAR BACKLASH
Adjust final drive gear backlash as follows:
1. Using the special tool(09521-43001), temporarily tighten the side bearing nut until it is in the state just before prereading of the side bearing.
2. Measure the final drive gear backlash.
Standard value: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
NOTE: Measure at lease 4 point on the drive gear periphery.
3. Using the special tool (09521-43000), adjust the backlash to standard value by moving the side bearing nut as shown.
NOTE: First turn the side bearing nut for loosening, and then turn (by the same amount) the side bearing nut for tightening.
4. Using the special tool(09521-43001) to apply the preload, turn down both right and left side bearing nut on half the distance between centers of two neighboring holes.
5. Choose and install the lock plates two kinds.
6. Check the final drive gear tooth contact. If poor contact is evident, make adjustment.
7. Measure the drive gear runout.
Limit: 0.05 mm (0.0020 inch)
8. When drive gear runout exceeds the limit, remove the differential case and then the drive gears, moving them to different positions and reinstalling them.