Installation of Differential Case
INSTALLATION OF DIFFERENTIAL CASEThis procedure will have to be repeated if:
^ Maximum preload is achieved before the minimum pinion nut torque is reached.
^ Minimum preload is not achieved before maximum pinion nut torque is reached.
1. Select side bearing adjusting shim. Refer to "SIDE BEARING PRELOAD".
2. Install differential case assembly with side bearing outer races into gear carrier.
3. Insert left and right side bearing adjusting shims in place between side bearing outer races and differential carrier assembly.
4. Drive in side bearing spacer with Tool.
Tool number: KV38100600 (J25267)
5. Align matchmark on bearing cap with that on differential gear carrier and install side bearing cap on gear carrier with soft hammer.
Side bearing cap bolts: 93 - 103 Nm (9.5 - 10.5 kg-m, 69 - 76 ft. lbs.)
6. Measure ring gear-to-drive pinion backlash with a dial indicator.
Ring gear-to-drive pinion backlash
Gear ratio 3.900, 4.625: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
Gear ratio 4.636: 0.10 - 0.15 mm (0.0041 - 0.0059 inch)
^ If backlash is too small, decrease thickness of right shim and increase thickness of left shim by the same amount.
^ If backlash is too great, reverse the above procedure
^ Never chance the total amount of shims as it will change the bearing preload.
7. Check total preload with Tool.
^ When checking preload, turn drive pinion in both directions several times to seat bearing rollers correctly.
Total preload: 1.4 - 2.9 Nm (15 - 29 kg-cm, 13 - 25 inch lbs.)
Tool number : ST3127S000 (J25765-A)
^ If preload is too great, remove the same amount of shim from each side.
^ If preload is too small, add the same amount of shim to each side.
^ Never add or remove a different number of shims for each side as it will change ring gear-to-drive pinion backlash.
8. Recheck ring gear-to-drive pinion backlash because increase or decrease in thickness of shims will cause change of ring gear-to-pinion backlash.
9. Check runout of ring gear with a dial indicator.
Ring gear runout limit: 0.08 mm (0.0031 inch)
^ If backlash varies excessively in different places, the variance may have resulted from foreign matter caught between the ring gear and the differential case.
^ If the backlash varies greatly when the runout of the ring gear is within a specified range, the hypoid gear set or differential case should be replaced.
10. Check tooth contact.
11. Install new rear cover gasket and rear cover.
12. Tighten rear cover bolts.
Rear cover bolts: 44 - 54 Nm (4.5 - 5.5 kg-m, 33 - 40 ft. lbs.)