Assembly
ASSEMBLY
Drive Pinion Assembly
1. Press a 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 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 drive pinion rear bearing inner race and 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 drive pinion front bearing inner race in axle housing.
7. Install front bearing thrust washer to axle housing.
8. Apply multi-purpose grease to front oil seal lip. Install 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 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 drive pinion nut and drive pinion nut washer. Tighten the drive pinion nut using Tool until total preload is within specification.
^ 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 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. Assemble side gear thrust washers with the same thickness as the ones installed prior to disassembly or reinstall the old ones on side gears.
2. Assemble side gear and side gear thrust washer into differential case.
3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and assemble them into differential case after assembling pinion mate thrust washer to pinion mate gear.
4. Align lock pin holes on differential case and shaft, and assemble 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 Tool.
Tool number: ST23550000 ( - )
CAUTION: Do not reuse lock pin.
7. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly.
8. Apply thread locking sealant to back face of drive gear.
^ Use Genuine High Strength Thread Locking Sealant, Loctite 648 or equivalent.
9. Align the matching mark of differential case with the mark of drive gear, then install drive gear.
10. Apply thread locking sealant into the thread hole of drive gear.
^ Use Genuine High Strength Thread Locking Sealant, Loctite 648 or equivalent.
CAUTION: Make sure the drive gear back and threaded holes are clean.
11. Install the drive gear bolts, and then tighten to the specified torque. Refer to RFD-50, "COMPONENTS".
CAUTION:
^ Do not reuse the bolts.
^ Tighten bolts in a crisscross fashion.
12. Press side bearing inner races to differential case using Tools.
Tool number
A: KV38100300 (J-25523)
B: ST33081000 ( - )
CAUTION: Do not reuse side bearing.
13. Install side bearing adjusters into axle housing.
14. Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into axle housing.
15. 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.
16. Tighten each side bearing adjuster using Tool.
Tool number: - (C-4164)
17. Adjust backlash of drive gear and drive pinion.
18. Check total preload.
19. Check tooth contact.
20. 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.
21. Install carrier cover on axle housing and tighten carrier cover bolts with the specified torque. Refer to RFD-50, "COMPONENTS".