Assembly

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ASSEMBLY
Drive Pinion Assembly





1. Install new front and rear bearing outer races using Tools.
Tool number
A: ST30611000 (J-25742-1)
B: ST30621000 (J-25742-5)
C: ST30613000 (J-25742-3)

CAUTION:
^ Tap bearing outer race until it becomes flat to axle housing.
^ Do not reuse drive 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 new drive pinion rear bearing inner race to it using Tool.
Tool number: ST30901000 (J-26010-01)

CAUTION:
^ Pay attention to the direction of pinion height adjusting washer. (Assemble as shown.)
^ Do not reuse drive pinion rear bearing inner race.





4. Assemble new collapsible spacer to drive pinion.

CAUTION: Do not reuse collapsible spacer.

5. Apply gear oil to drive pinion rear bearing, and assemble drive pinion into axle housing.
6. Apply gear oil to drive pinion front bearing, and assemble new drive pinion front bearing inner race to drive pinion assembly.

CAUTION: Do not reuse drive pinion front bearing inner race.





7. Press the pinion front bearing inner race onto drive pinion using suitable tool. Press the pinion front bearing inner race as far as the pinion nut can be tightened.





8. Install new front oil seal as shown using Tool.
Tool number: KV38100500 (J-25273)

CAUTION:
^ Do not reuse oil seal.
^ When installing, do not incline oil seal.
^ 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 new 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 ( - )
B: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 147 - 323 Nm (15 - 32 kg-m, 109 - 238 ft. lbs.)
Drive pinion bearing preload: 1.1 - 1.4 Nm (0.12 - 0.14 kg-m, 10 - 12 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 carrier 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 carrier cover.

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: Drive gear back and threaded holes shall be cleaned and degreased sufficiently.





9. Install the drive gear bolts, and then tighten to the specified torque. Refer to RFD-15, "COMPONENTS".

CAUTION:
^ Tighten bolts in a crisscross fashion.
^ After tightening the bolt to the specified torque, turn the bolt 31 to 36 more degrees.





10. Press new side bearing inner races to differential case using Tools.
Tool number
A: ST33230000 (J-25805-01)
B: ST33061000 (J-8107-2)

CAUTION: Do not reuse side bearing inner race.





11. Install differential case assembly with side bearing outer races into axle housing.
12. Measure side bearing preload. If necessary, select the appropriate side bearing adjusting washers.





13. Insert selected left and right side bearing adjusting washers in place between side bearings and axle housing using Tool.
Tool number: KV38100600 (J-25267)





14. Align matching mark on side bearing cap with that on axle housing.
15. Install side bearing caps and tighten side bearing cap bolts to the specified torque. Refer to RFD-15, "COMPONENTS".
16. 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.





17. 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.

18. Install carrier cover on axle housing and tighten bolts with the specified torque. Refer to RFD-15, "COMPONENTS".