Installation of Differential Case Assembly

INSTALLATION OF DIFFERENTIAL CASE ASSEMBLY





1. Select side bearing adjusting washer.
2. Install differential case assembly with side bearing outer races into final drive housing.





3. Insert left and right side bearing adjusting shims in place between side bearing outer races and final drive housing.





4. Drive in side bearing spacer using Tool.
Tool number: KV38100600 (J25267)





5. Align mark on bearing cap with that on final drive housing and install bearing cap on final drive housing.





6. Apply multi-purpose grease to cavity at sealing lips of side flange oil seal. Install side flange oil seal using Tool.
Tool number: KV38100200 (J26233)





7. Measure ring gear to drive pinion backlash with a dial indicator.
Ring gear to drive pinion backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch)
^ If backlash is too small, decrease thickness of right side bearing adjusting shim and increase thickness of left side bearing adjusting shim by the same amount.
^ If backlash is too great, reverse the above procedure.
^ Never change the total amount of side bearing adjusting shims as it will change the bearing preload.





8. Check total preload using Tool.
^ When checking preload, turn drive pinion in both directions several times to set bearing rollers.
Total preread: 1.4 - 1.7 Nm (14 - 17 kg-cm, 12 - 15 inch lbs.)
Tool number: ST3127SOOO (J25765-A)





^ If preload is too great, remove the same amount of side bearing adjusting shim from each side.
^ If preload is too small, add the same amount of side bearing adjusting shim to each side.
^ Never add or remove a different number of side bearing adjusting shims for each side as it will change ring gear to drive pinion backlash.

9. Recheck ring gear to drive pinion backlash because increase or decrease in thickness of side bearing adjusting shims will cause chance of ring gear to drive pinion backlash.
^ 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 ring gear runout with a dial indicator.
Ring gear runout limit: 0.05 mm (0.0020 inch)
^ If ring gear runout varies excessively in different places, the variance may have resulted from foreign matter caught between the ring gear and the differential case.

11. Check tooth contact.
12. Install rear cover and a new gasket.
Rear cover bolts: 39 - 49 Nm (4 - 5 kg-m, 29 - 36 ft. lbs.)





13. Install differential side shaft assembly.
Extension tube retainer bolt and nut: 34 - 44 Nm (3.5 - 4.5 kg-m, 25 - 33 ft. lbs.)
14. Install differential side flange.
Differential side flange bolt: 31 - 42 Nm (3.2 - 4.3 kg-m, 23 - 31 ft. lbs.)