FRONT DIFFERENTIAL ASSEMBLY [G6, WLT-1, WLT-2]

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1.  Assemble in the order indicated in the table.

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1
Gear case
2
Thrust washer
3
Side gear
4
Thrust washer
5
Pinion gear
6
Pinion shaft
7
Knock pin
(See Knock Pin Assembly Note.)
8
Ring gear
(See Ring Gear Assembly Note.)
9
Side bearing inner race
(See Side Bearing Inner Race Assembly Note.)
10
Bolt
11
Differential carrier
12
Front bearing outer race
(See Front Bearing Outer Race Assembly Note.)
13
Rear bearing outer race
(See Rear Bearing Outer Race Assembly Note.)
14
Spacer
(See Spacer Assembly Note)
15
Rear bearing inner race
(See Rear Bearing Inner Race Assembly Note.)
16
Drive pinion
(See Drive Pinion Assembly Note.)
17
Collapsible spacer
18
Front bearing inner race
19
Oil seal (companion flange)
(See Oil Seal (Companion Flange) Assembly Note.)
20
Companion flange
21
Washer
22
Locknut
(See Locknut Assembly Note.)
23
Side bearing outer race
(See Side Bearing Outer Race, Adjusting Screw, Bearing Cap Assembly Note.)
24
Adjusting screw
(See Side Bearing Outer Race, Adjusting Screw, Bearing Cap Assembly Note.)
25
Bearing cap
(See Side Bearing Outer Race, Adjusting Screw, Bearing Cap Assembly Note.)
26
Lock plate
27
Differential casing
28
Oil seal (differential casing)
(See Oil Seal (Differential Casing) Assembly Note.)
29
Oil baffle
30
Bolt


Knock Pin Assembly Note

1.  Assemble the side gears, thrust washer, pinion gears, pinion shaft and knock pin. After assembling the knock pin, make a crimp so that the pin will not come out of the gear case.

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Ring Gear Assembly Note

1.  Coat the ring gear and gear case facing surfaces with locking agent.

2.  Install the ring gear and tighten the bolt to the specified torque.

Tightening torque
68.6—83.3 N·m {7.00—8.49 kgf·m, 50.6—61.4 ft·lbf}


Side Bearing Inner Race Assembly Note

Caution
•  Bearings should be assembled to the original positions.

1.  Press the side gearings into the gear case using the SST.

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Front Bearing Outer Race Assembly Note

1.  Press the front bearing outer race into the carrier using the SST and a press.

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Rear Bearing Outer Race Assembly Note

1.  Press the rear bearing outer race into the carrier using the SST and a press.

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Spacer Assembly Note


Pinion height adjustment

Note
•  Use the installed spacer when adjusting.
•  Be careful to install SSTs in the correct position and facing in the correct direction.

1.  Assemble the spacer, rear bearing inner race, and the SST (49 8531 568) on to the SST (49 8531 565) as shown in the figure.

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2.  Assemble the front bearing inner race, SST (49 8531 567), companion flange, washer and nut to the SST (49 8531 565).

3.  Tighten the nut to the extent that the SST (49 8531 565) can be turned by hand.

4.  Place the SST on the surface plate and set the dial gauge to zero.

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5.  Place the SST (49 0305 555) on top of the SST (49 8531 565), and then set the SST (49 0727 570) on top of the SST (49 0305 555).

6.  Place the measuring probe of the dial gauge at the point where the side bearing is installed in the differential carrier and measure at the lowest position. Measure the left and right sides.

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7.  Add the two (left and right) values obtained by the measurements taken in Step 6 and then divide the total by 2. From this sum, subtract the sum of the number inscribed on the end of the drive pinion divided by 100. (If there is no figure inscribed, use 0.) This is the pinion height adjustment value.

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Note
•  For example, the measured results obtained step 6 are 0.06 mm {0.0024 in} and 0.04 mm {0.0016 in}, and the figure inscribed on the end of the drive pinion is -2, the formula is (0.06+0.04)/2-(-2/100)=0.07.
Therefore, replace it with a spacer 0.07 mm {0.003 in} thicker than the currently used one.

Spacer table

Identification mark

Thickness (mm {in})

Identification mark

Thickness (mm {in})
08
3.080 {0.1213}
29
3.290 {0.1295}
11
3.110 {0.1224}
32
3.320 {0.1307}
14
3.140 {0.1234}
35
3.350 {0.1319}
17
3.170 {0.1248}
38
3.380 {0.1331}
20
3.200 {0.1260}
41
3.410 {0.1343}
23
3.230 {0.1271}
44
3.440 {0.1354}
26
3.260 {0.1283}
47
3.470 {0.1366}


Rear Bearing Inner Race Assembly Note

Caution
•  Press in until the force required suddenly increases.
•  Install the spacer selected for the pinion height adjustment, confirm that the installation direction is correct.

1.  Press the rear bearing inner race in using the SSTs.

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Drive Pinion Assembly Note


Drive pinion preload adjustment

Caution
•  Do not install the oil seal.

1.  Assemble the following parts to the drive pinion.

•  New collapsible spacer
•  Front bearing
•  New spacer
•  Companion flange
•  New washer
•  New locknut

2.  Turn the serrated part of the drive pinion by hand to seat the bearing.

3.  Tighten the locknut temporarily tightened in Step 1 from the lower limit of the specified tightening torque using the SST, and obtain the specified preload. Record the tightening torque at this time.

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Tightening torque
128—284 N·m {13.1—28.9 kgf·m, 94.5—209 ft·lbf}
Front differential drive pinion preload
0.89—1.37 N·m {9.1—13.9 kgf·cm, 7.9—12.1 in·lbf}
•  If the specified preload cannot be obtained within the specified tightening torque, replace with a new collapsible spacer and adjust again.

4.  Remove the locknut, washer, and companion flange.


Oil Seal (Companion Flange) Assembly Note

1.  Apply differential oil to the oil seal lip and press the oil seal in until it touches the end of the differential carrier using the SST.

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Locknut Assembly Note

1.  Assemble the companion flange and washer.

2.  Tighten a new locknut using the SST.

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Tightening torque
128—284 N·m {13.1—28.9 kgf·m, 94.5—209 ft·lbf}


Side Bearing Outer Race, Adjusting Screw, Bearing Cap Assembly Note

1.  Install the differential gear component to the carrier. After loosely tightening the bearing outer race and bearing cap mounting bolts, completely tighten the adjustment screw by hand. Then, while turning the ring gear, alternately tighten the left and right adjustment screws using the SST.

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2.  Adjust the drive pinion, ring gear backlash and the side bearing preload as follows:

(1)  Mark the ring gear at four points at approx. 90° intervals and mount a dial indicator to the carrier so that the feeler comes in contact at a 90° angle with one of the ring gear teeth.
(2)  Turn both bearing adjusters equally until the backlash becomes 0.09—0.11 mm {0.0035—0.0043 in} using the SST.
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(3)  Inspect for the backlash at the three other marked points and make sure that the minimum backlash is more than 0.05 mm {0.002 in} and difference of the maximum and minimum backlash value is less than 0.07 mm {0.0028 in}.
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(4)  After adjusting the backlash, tighten the adjustment screws equally until the distance between both pilot sections on the bearing caps (L) become as specified.
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Bearing cap bolt tightening torque
37—52 N·m {3.8—5.3 kgf·m, 27.3—38.3 ft·lbf}
Distance L
185.43—185.50 mm {7.300—7.303 in}

3.  The inspection and adjustment procedure is as follows:

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(1)  Coat both surfaces of 6—8 teeth of the ring gear uniformly with a tooth marking compound.
(2)  While moving the ring gear back and forth by hand, rotate the drive pinion several times and inspect the tooth contact.
(3)  If the tooth contact is good, wipe off the red lead coating.
(4)  If it is not good, adjust the pinion height, then adjust the backlash.


Toe and flank contact

1.  Replace the spacer with a thinner one, and move the drive pinion outward.

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Heel and face contact

1.  Replace the spacer with a thicker one. Bring the drive pinion inward.

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Oil Seal (Differential Casing) Assembly Note

1.  Tap in the new oil seal to the front differential casing using the SSTs.

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