Assembly

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ASSEMBLY
Drive Pinion Assembly





1. Install front and rear bearing outer races using Tools.
Tool number
A: ST30611000 (J-25742-1)
B: ST30613000 (J-25742-3)
C: KV38100200 (J-26233)

CAUTION:
^ First tap the bearing outer race until it becomes flat to the gear carrier.
^ Do not reuse pinion front and rear bearing outer race.

2. Select drive pinion height adjusting washer.





3. Install selected drive pinion height adjusting washer to drive pinion. Press pinion rear bearing inner race to it using Tool.
Tool number: ST30901000 (J-26010-01)

CAUTION:
^ Install the pinion height adjusting washer in the proper direction as shown.
^ Do not reuse pinion rear bearing inner race.





4. Assemble collapsible spacer to drive pinion.

CAUTION: Do not reuse collapsible spacer.

5. Apply gear oil to pinion rear bearing, and assemble drive pinion into gear carrier.





6. Apply gear oil to pinion front bearing, and assemble pinion front bearing inner race to drive pinion assembly.

CAUTION: Do not reuse pinion front bearing inner race.





7. Press the pinion front bearing inner race to drive pinion as far as drive pinion lock nut can be tightened using Tool.
Tool number: ST33200000 (J-26082)





8. Install front oil seal until it becomes flush with the case end using Tools.
Tool number
A: ST30720000 (J-25405)
B: ST27863000 ( - )

CAUTION:
^ Do not reuse oil seal.
^ Do not incline oil seal when installing.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.





9. Install companion flange.

NOTE: When reusing drive pinion, align the matching mark of drive pinion with the matching mark A of companion flange, then install companion flange.





10. Apply gear oil to the thread and seat of drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion.

CAUTION: Do not reuse drive pinion lock nut.

11. Adjust the new drive pinion lock nut tightening torque and pinion bearing preload torque using Tools.
Tool number
A: KV38108300 (J-44195)
B: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 186 - 294 Nm (19 - 29 kg-m, 138 - 216 ft. lbs.)
Drive pinion bearing preload: 1.08 - 1.66 Nm (0.11 - 0.16 kg-m, 10 - 14 inch lbs.)

CAUTION:
^ Adjust the lower limit of the drive pinion lock nut tightening torque first.
^ If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Do not loosen drive pinion lock nut to adjust the preload torque.
^ After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.

12. Install differential case assembly.

CAUTION: Do not install rear cover yet.

13. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion flange runout.
Recheck above items. Readjust the above description, if necessary.
14. Check total preload torque.
15. Install rear cover.
16. Install side shaft assembly.

Differential Assembly





1. Install side gear thrust washers with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the side gears.





2. Install side gears and thrust washers into differential case.

CAUTION: Make sure that the circular clip is installed to side gears.

3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and install them into differential case after installing thrust washer to pinion mate gear.





4. Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers.





6. Drive a lock pin into pinion mate shaft, using suitable tool. Make sure lock pin is flush with differential case.

CAUTION: Do not reuse lock pin.





7. Align the matching mark of differential case with the mark of drive gear, then place drive gear.





8. Apply thread locking sealant into the thread hole of drive gear.
^ Use Genuine High Strength Thread Locking Sealant or equivalent.

CAUTION: Make sure the drive gear back and threaded holes are clean.





9. Install drive gear on the bolts, and then tighten to the specified torque. Refer to FFD-16, "COMPONENTS".

CAUTION:
^ Tighten bolts in a crisscross pattern.
^ After tightening the bolts to the specified torque, tighten the bolts an additional 34 to 39 degrees.





10. Press side bearing inner races to differential case, using Tools.
Tool number
A: ST33230000 (J-35867)
B: ST33061000 (J-8107-2)

CAUTION: Do not reuse side bearing inner race.

11. Install housing spacer.





12. Apply gear oil to side bearings, and install differential case assembly with side bearing outer races into gear carrier.





13. Insert left and right original side bearing adjusting washers in place between side bearings and gear carrier, using Tool.
Tool number: KV38100600 (J-25267)





14. Align matching mark on bearing cap with that on gear carrier.
15. Install bearing caps and tighten bearing cap bolts to the specified torque. Refer to FFD-16, "COMPONENTS".





16. Drive side oil seal until it becomes flush with the case end using Tools.
Tool number
A: ST30720000 (J-25405)
B: ST27863000 ( - )

CAUTION:
^ Do not reuse oil seal.
^ Do not incline oil seal when installing.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.

17. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque.
Recheck above items. Readjust the above description, if necessary.





18. Apply sealant to mating surface of rear cover.
^ Use Genuine Silicone RTV or equivalent.

CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating surfaces.

19. Install rear cover on gear carrier and tighten bolts with the specified torque. Refer to FFD-16, "COMPONENTS".
20. Install side shaft assembly.

Side Shaft





1. Press side shaft bearing to side shaft.

CAUTION: Do not reuse bearing.

2. Install snap ring (shaft side).
3. Install side shaft assembly into gear carrier.
4. Install snap ring (hole side).





5. Drive side oil seal until it becomes flush with the case end using Tools.
Tool number
A: ST30720000 (J-25405)
B: ST27863000 ( - )

CAUTION:
^ Do not reuse oil seal.
^ Do not incline oil seal when installing.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.