Differential Carrier Assembly Reassembly
ASSEMBLY
Required Special Tools:
- MB990810: Side Bearing Puller
- MB990829: Pinion & Side Bearing Installer
- MB990930: Installer Adapter
- MB990934: Installer Adapter
- MB990938: Installer Bar
- MB991115: Oil Seal Installer
- MB991180: Bush Remover & Installer Base
- MB992111: Side Bearing Holder
- MB992112: Lock Nut Wrench
- MB992113: Drive Pinion Holder
- MB992115: Dummy Pinion Gauge body
- MB992116: Dummy Pinion Gauge Head
- MB992117: Cylinder Gauge
- MB992128: Hex Socket Head Bolt
- MD998816: Installer Adapter
LUBRICANT/SEALANT APPLICATION POINTS
ASSEMBLY SERVICE POINT
]]A[[ DRIVE PINION REAR BEARING OUTER RACE PRESS-FITTING
Use special tools MB990934 and MB990938 to press-fit the drive pinion rear bearing outer race.
]]B[[ DRIVE PINION FRONT BEARING OUTER RACE PRESS-FITTING
Use special tools MB990930 and MB990938 to press-fit the drive pinion front bearing outer race.
]]C[[ DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height in the following steps.
1. Use special tools MB992115, MB992116 and MB992128 to assemble the drive pinion front and rear bearing inner races onto the differential carrier:
CAUTION:
The bearing must be free from differential gear oil.
2. Measure the drive pinion rotation torque.
Standard value:
NOTE:
After seating the bearing, measure the rotation torque.
3. Set special tool MB992117 on the differential carrier side bearing, and use special tool MB992111 to assemble it onto the differential carrier.
Make sure that the cut-off part of the cylinder gauge is positioned as shown in the figure, and the cylinder gauge is closely contacted with the side bearing.
Tightening torque: 48± 6Nm (36± 4 ft-lb)
4. Select the drive pinion rear shim(s) that corresponds to the gap between the special tools.
NOTE:
1. Clean the side bearing.
2. When setting the special tool, make sure that its cut-off part is positioned as shown in the figure, and it is closely contacted with the side bearing.
3. Try to minimize the number of the drive pinion rear shim(s) to be used.
5. Fit the selected drive pinion rear shim(s) onto the drive pinion. Use special tool MD998816 to press-fit the drive pinion rear bearing inner race.
]]D[[ DRIVE PINION ROTATION TORQUE ADJUSTMENT/OIL SEAL PRESS-FITTING
Adjust the drive pinion rotation torque in the following steps:
1. Insert the drive pinion into the differential carrier. From rear side of the carrier, assemble the drive pinion spacer, drive pinion front shim and drive pinion front bearing inner race.
NOTE:
Do not assemble the oil seal.
2. Use special tools MB992112 and MB992113 to tighten the differential nut to the specified torque.
3. Rotate the drive pinion several turns, and then measure the drive pinion rotation torque.
Standard value:
4. When the rotation torque is not within the standard value range, adjust the torque by selecting the drive pinion front shim(s).
NOTE:
When selecting the drive pinion front shim(s), select the drive pinion spacer to minimize the number of the shims to be used. There are two drive pinion spacers available:
5. Use special tools MB992112 and MB992113 to tighten the differential nut to the specified torque.
Tightening torque: 190± 3Nm (140± 22 ft-lb)
6. Use special tool MB991180 to press-fit the oil seal.
7. Rotate the drive pinion several turns, and then measure the drive pinion rotation torque.
Standard value:
8. When the rotation torque is not within the standard value, check the differential locking nut tightening torque or the oil seal assembly condition.
]]E[[ DIFFERENTIAL GEAR BACKLASH ADJUSTMENT
Adjust the differential gear backlash in the following steps.
1. Assemble the side gear, side gear spacer, pinion gear and pinion washer into the differential case.
2. Temporarily assemble the pinion shaft.
NOTE:
Do not assemble the lock pin at this stage.
3. Drive a wooden wedge between one of the side gears and the pinion shaft to fix the side gear.
4. Set a dial gauge (with the measuring rod extended) against the pinion gear and measure the backlash. Repeat the same procedure to measure the backlash at the other pinion gear.
Standard value: 0 - 0.076 mm (0 - 0.0030 inch)
Limit: 0.2 mm (0.01 inch)
5. When the backlash exceeds the limit value, adjust it by selecting the side gear spacer.
6. When the adjustment is not possible, replace the side gear and the pinion gear as a set.
7. After the adjustments, make sure that the backlash is within the limit value and the differential gear rotates smoothly.
]]F[[ LOCK PIN INSTALLATION
1. Align the lock pin holes in the pinion shaft and in the differential case, and drive in the lock pin.
2. Use a punch to crimp two points.
]]G[[ DRIVE GEAR INSTALLATION
1. Remove adhesive on the drive gear tightening bolts.
2. Use a tap to remove adhesive in the drive gear screw holes, and clean the holes by blowing air.
3. Apply the specified thread locking compound in the drive gear screw holes.
Specified adhesive: 3M(TM) AAD Part No.8730, 8731 or equivalent
4. Align the mating marks and assemble the drive gear to the differential case.
Tightening torque: 41± 5Nm (30± 3 ft-lb)
]]H[[ DIFFERENTIAL SIDE BEARING INNER RACE INSTALLATION
Use special tool MB990829 to press-fit the differential side bearing inner race.
]]I[[ FINAL DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the final drive gear backlash in the following steps:
1. To the differential carrier, install the differential case with the side bearing outer race assembled.
2. Press the differential case to one side, and measure clearance between the side bearing outer race and the differential carrier.
3. Select two pairs of the side bearing spacers. (Thickness: 1/2 of the measured clearance with 0.05 mm (0.002 inch) preload added)
4. Use special tool MB992111 to install the differential case to the differential carrier.
Tightening torque: 48± 6Nm (36± 4 ft-lb)
5. Measure the final drive gear backlash at four or more points.
Standard value: 0.08 - 0.15 mm (0.003 - 0.006 inch)
6. When the backlash is not within the standard value range, move the side bearing spacers as shown in the figure to adjust the backlash.
NOTE:
Increase the side bearing spacers by the same amount as for the decrease.
7. Check the final drive gear teeth contact, and if not proper, adjust it.(Refer to Differential Carrier Assembly Disassembly.)
8. Measure the drive gear runout on the backside.
Limit: 0.05 mm (0.002 inch)
9. When the runout exceeds the limit, change position of the drive gear and differential case, and measure the runout again.
10. If the adjustment is not possible, replace the differential case or the drive gear and the drive pinion as a set.
]]J[[ OIL SEAL PRESS-FITTING
Use special tools MB990938 and MB991115 to press-fit the oil seal.