Assembly

ASSEMBLY
Drive Pinion Assembly





1. Press a new drive pinion rear bearing outer race into axle housing using Tools.
Tool number
A: ST01500001 ( - )
B: ST30022000 ( - )

CAUTION: Do not reuse drive pinion rear bearing.





2. Press a new drive pinion front bearing outer race into axle housing using Tool.
Tool number: ST33022000 ( - )

CAUTION: Do not reuse drive pinion front bearing.

3. Select drive pinion height adjusting washer.





4. Press a new drive pinion rear bearing inner race and new drive pinion height adjusting washer to drive pinion using Tool.
Tool number: - (C-4040)

CAUTION: Do not reuse drive pinion rear bearing.

5. Apply gear oil to drive pinion rear bearing and drive pinion front bearing.
6. Install new drive pinion front bearing inner race in axle housing.
7. Install front bearing thrust washer to axle housing.





8. Apply multi-purpose grease to new front oil seal lip. Install new front oil seal into axle housing using Tool.
Tool number: ST15310000 ( - )

CAUTION:
^ Do not reuse oil seal.
^ When installing, do not incline oil seal.





9. Install new collapsible spacer to drive pinion. And then install drive pinion assembly in axle housing.

CAUTION:
^ Do not reuse collapsible spacer.
^ Do not damage front oil seal.





10. Align the matching mark of drive pinion with the mark of companion flange.





11. Install companion flange onto drive pinion. Tap companion flange until fully seated using suitable tool.

CAUTION: Do not damage companion flange and front oil seal.





12. Install new drive pinion nut and new drive pinion nut washer. Tighten drive pinion nut until total preload is within specification using Tool.
^ The threaded portion of drive pinion and drive pinion nut should be free from oil or grease.
Tool number: KV40104000 ( - )

CAUTION: Do not reuse drive pinion nut and drive pinion nut washer.





13. Tighten new drive pinion nut by very small degrees until the specified preload is achieved. When checking the preload, turn drive pinion in both directions several times to set the bearing rollers using Tool.
Tool number: ST3127S000 (J-25765-A)
Pinion bearing preload: 1.7 - 3.1 Nm (0.18 - 0.31 kg-m, 15 - 27 inch lbs.)
a. This procedure will have to be repeated if:
^ Maximum preload is achieved before the minimum drive pinion nut torque is reached.
^ Minimum preload is not achieved before maximum drive pinion nut torque is reached.

Differential Assembly





1. Apply thread locking sealant to back face of drive gear.
^ Use Genuine High Strength Thread Locking Sealant, Loctite 648 or equivalent.





2. Align the matching mark of differential case assembly with the mark of drive gear, then install drive gear.





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

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





4. Install the new drive gear bolts, and then tighten to the specified torque. Refer to RFD-121, "COMPONENTS".

CAUTION:
^ Do not reuse the bolts.
^ Tighten bolts in a crisscross fashion.





5. Press side bearing inner races to differential case assembly using Tool.
Tool number: ST33081000 ( - )

CAUTION: Do not reuse side bearing.





6. Install differential lock solenoid and washer.
7. Press side bearing inner races to differential case assembly using Tools.
Tool number
A: KV38100300 (J-25523)
B: ST33081000 ( - )
8. Apply sealant to threads of differential lock position switch.
^ Use Genuine Silicone RTV or equivalent.

CAUTION: Remove old sealant adhering to axle housing and differential lock position switch. Also remove any moisture, oil, or foreign material adhering to application and axle housing and differential lock position switch.





9. Install differential lock position switch on axle housing and tighten differential lock position switch bolts with the specified torque. Refer to RFD-121, "COMPONENTS".





10. Install side bearing adjusters into axle housing.





11. Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into axle housing.
12. Apply multi-purpose grease to new sensor connector.

CAUTION: Do not reuse sensor connector.





13. Connect differential lock solenoid harness and sensor connector. Then install it to axle housing, tighten to the specified torque. Refer to RFD-121, "COMPONENTS".





14. Align paint matching mark on side bearing caps with that on axle housing and install side bearing caps on axle housing.

CAUTION: Do not tighten at this point. This allows further tightening of side bearing adjusters.





15. Tighten each side bearing adjusters using Tool.
16. Adjusting backlash of drive gear and drive pinion.
17. Check total preload.
18. Check tooth contact.
Tool number: - (C-4164)





19. Apply sealant to mating surface of carrier 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.

20. Install carrier cover on axle housing and tighten carrier cover bolts with the specified torque. Refer to RFD-121, "COMPONENTS".