Part 2
ASSEMBLY (continued)T-TYPE (B2)
20) If proper tooth contact is not obtained, readjust the drive pinion height by changing the RH and LH side retainer shims and the hypoid gear backlash.
(1) Drive pinion height
ST1 398507702 DUMMY SHAFT
ST2 398507701 DIFFERENTIAL CARRIER GAUGE
T = To + N - (H � 0.01) - 0.20 mm (0.008 in)
(2) Hypoid gear backlash
Backlash:
0.10 - 0.20 mm (0.004 - 0.008 in)
21) Remove the RH and LH side retainers.
22) Install the O-ring to left and right side retainers.
NOTE:
Use new O-rings.
23) Install the oil seal to the side retainer of both sides.
24) Align the arrow mark on the differential carrier with the arrow mark on the side retainer when installing the side retainer.
25) Apply liquid gasket to the bolts indicated by arrows, and tighten the bolts.
Liquid gasket:
THREE BOND 1110B (Part No. K0879Y0020) or equivalent
Tightening torque:
10.5 Nm (1.1 kgf-m, 7.7 ft-lb)
26) Install the gasket and rear cover, and tighten the bolts to specified torque.
NOTE:
Use a new gasket.
Tightening torque:
29.5 Nm (3.0 kgf-m, 21.8 ft-lb)
27) Install the air breather cap.
NOTE:
When installing the air breather cap, do not tap section (A). Be sure to tap section (B) to install.
28) Install the drain plug.
NOTE:
Apply liquid gasket to the drain plug.
Liquid gasket:
THREE BOND 1105 (Part No. 004403010) or equivalent
Tightening torque:
49 Nm (5.0 kgf-m, 36.1 ft-lb)
29) Install the filler plug.
NOTE:
After installing the rear differential assembly to the vehicle, fill the gear oil, then apply liquid gasket, and tighten to the specified torque.
T-TYPE (H3)
NOTE:
^ Assemble in the reverse order of disassembly.
^ Check and adjust each part during assembly.
^ Keep the shims and washers in order, so that they are not improperly installed.
^ Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed.
^ Apply gear oil when installing the bearings and thrust washers.
^ Be careful not to mix up the RH and LH bearing races.
^ Use a new O-ring and gasket.
^ Replace the oil seal with a new part at every disassembly.
^ Be careful not to mix up the oil seal RH and LH.
^ Apply differential gear oil to the lips when installing the oil seal.
1) Adjusting preload for front and rear bearings
NOTE:
Adjust the bearing preload between front and rear bearings with spacer and washer. Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted.
2) Using the ST, press-fit the rear bearing race to the differential carrier.
ST 398417700 DRIFT
3) Using the ST, press-fit the front bearing race to the differential carrier.
ST 398477702 DRIFT
4) Selecting the pinion height adjusting washer
(1) Measure the thickness of the inserted pinion height adjusting washer.
(2) Read the markings on both the current drive pinion gear and the new pinion gear.
NOTE:
No marking means 0 (zero).
(3) Calculate the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the installed washer with a new washer of the calculated thickness.
T = T1 + (T2 x 0.01 - T3 x 0.01)
(Example of calculation)
T1 = 3.30 mm (0.1299 in), T2 = +2, T3 = -1
T = 3.30 mm (0.1299 in) + {(2 x 0.01) - (-1 x 0.01)} = 3.33 mm (0.1311 in)
Result: Thickness = 3.33 mm (0.1311 in)
The washer with part number 38336AA310 is used.
5) Install the selected pinion height adjusting washer on drive pinion, and push the rear bearing cone into position with ST.
ST 18674AA000 INSTALLER
6) Insert the drive pinion into the differential carrier, and install the originally attached preload adjusting spacer and washer.
7) Insert the spacer and press-fit the pilot bearing using ST.
ST1 399780104 WEIGHT
ST2 899580100 INSTALLER
ST3 398507703 DUMMY COLLAR
ST4 498937110 HOLDER DRIVE PINION
8) Press-fit the companion flange with ST1, ST2, and ST3.
NOTE:
Be careful not to damage the bearing.
ST1 899874100 INSTALLER
ST2 399780104 WEIGHT
ST3 498937110 HOLDER DRIVE PINION
9) Attach the self-locking nut and use the ST to fix the companion flange in place, then tighten the self-locking nut.
Tightening torque:
181.5 Nm (18.5 kgf-m, 133.9 ft-lb)
ST 18633AA000 WRENCH COMPL
10) Rotate the drive pinion shaft 10 times or more to fit it in the respective taper roller bearing, and then measure the initial load or initial torque.
Initial load:
24.1 - 38.6 N (2.5 - 3.9 kgf, 5.4 - 8.7 lbf)
Initial torque:
0.98 - 1.57 Nm (0.10 - 0.16 kgf-m, 0.72 - 1.16 ft-lb)
11) When the bearing preload is out of the specified range, select the preload adjusting washer and spacer from the following table in order to make it within the specified range.
12) Remove the self-locking nut while securing the companion flange with ST.
ST 18633AA000 WRENCH COMPL
13) Extract the companion flange with a puller.
14) Using the ST, install the oil seal.
NOTE:
^ Use a new oil seal.
^ Press-fit until the oil seal end comes 1 mm (0.04 in) inward from end of carrier.
^ Apply differential gear oil to the oil seal lips.
ST 498447120 INSTALLER
15) Press-fit the companion flange with ST1, ST2, and ST3.
ST1 899874100 INSTALLER
ST2 399780104 WEIGHT
ST3 498937110 HOLDER DRIVE PINION
NOTE:
Be careful not to damage the bearing.
16) Apply seal material on the drive pinion shaft thread and new self-locking nut seat.
Seal material:
THREE BOND 1324 (Part No. 004403042) or equivalent
17) Attach the new self-locking nut and use the ST to fix the companion flange in place, then tighten the self-locking nut.
Tightening torque:
181.5 Nm (18.5 kgf-m, 133.9 ft-lb)
ST 18633AA000 WRENCH COMPL
18) Check the initial torque or initial load.
Initial load:
24.1 - 38.6 N (2.5 - 3.9 kgf, 5.4 - 8.7 lbf)
Initial torque:
0.98 - 1.57 Nm (0.10 - 0.16 kgf-m, 0.72 - 1.16 ft-lb)
19) Install the driven gear to the differential case.
NOTE:
^ Before installing bolts, apply seal material to bolt threads.
Seal material:
THREE BOND 1324 (Part No. 004403042) or equivalent
^ Make sure there is no clearance between the differential case and driven gear.
^ Tighten opposing bolts in order.
Tightening torque:
103 Nm (10.5 kgf-m, 76.0 ft-lb)
20) Using the ST, press-fit the side bearing to the differential case.
ST 398487700 DRIFT
21) Using the ST, press-fit the side bearing outer race to the side retainer.
CAUTION:
Make sure that the bearing outer races and cones are properly assembled.
ST 398417700 DRIFT
22) Side retainer shim adjustment
(1) The hypoid driven gear backlash and side bearing preload can be adjusted by the side retainer shim thickness.
(2) Install the differential case assembly into differential carrier in the reverse order of disassembly.
NOTE:
Be careful not to hit the teeth of hypoid driven gear against the differential carrier.
(3) Install the side retainer shim.
NOTE:
^ Be careful not to mix up the side retainer shim RH and LH.
^ Replace broken or corroded side retainer shims with a new part of the same thickness.
(4) During installation, align the arrow mark on the differential carrier with the arrow mark on the side retainer when installing the side retainer.
NOTE:
Be careful that side bearing outer race is not damaged by the bearing roller.
(5) Tighten the side retainer bolts.
Tightening torque:
10.5 Nm (1.1 kgf-m, 7.7 ft-lb)
(6) Measure the hypoid driven gear to drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of hypoid driven gear, and move hypoid driven gear while holding drive pinion still. Read the value indicated on dial gauge. If the backlash is outside the standard range, adjust the side retainer shim by the following method.
^ When backlash is less than 0.1 mm (0.004 in):
Reduce the thickness of shim on the back side of the hypoid driven gear and increase the thickness of shims on the teeth side of the hypoid driven gear.
^ When backlash exceeds 0.2 mm (0.008 in):
Increase the thickness of shim on the back side of the hypoid driven gear and reduce the thickness of shims on the teeth side of the hypoid driven gear.
Backlash:
0.10 - 0.20 mm (0.004 - 0.008 in)
(7) Measure the total preload of the drive pinion. If the total preload is not within specification, adjust the thickness of side retainer shims, increasing/reducing both shims by an even amount on both sides.
Total preload:
26.5 - 53 N (2.7 - 5.4 kgf, 6.0 - 11.9 lbf)
23) Recheck the hypoid driven gear to drive pinion backlash.
Backlash:
0.10 - 0.20 mm (0.004 - 0.008 in)
24) Check drive pinion and hypoid driven gears rotate smoothly and make sure of the hypoid driven gear runout on its back surface. If the runout on the back side of the hypoid driven gear exceeds the specification, check for any foreign material between the hypoid driven gear and differential case, and for any deformation of the case or gear.
Hypoid driven gear back surface runout:
0.05 mm (0.002 in)
25) Checking and adjusting the tooth contact of hypoid driven gear
(1) Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Check the contact pattern after rotating the hypoid driven gear several revolutions back and forth until a definite contact pattern appears on the hypoid driven gear.
(2) When the contact pattern is not correct, readjust.
NOTE:
Be sure to wipe off the lead-free red dye completely after the adjustment is completed.
^ Correct tooth contact
Check item: Tooth contact pattern is slightly shifted toward toe side under no-load rotation. (When driving, it moves towards the heel side.)
^ Face contact
Check item: Backlash is too large.
Contact pattern
Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side.
^ Flank contact
Check item: Backlash is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.
^ Toe contact (inside contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.
^ Heel contact (outside end contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side.
26) If proper tooth contact is not obtained, readjust the drive pinion height by changing the RH and LH side retainer shims and the hypoid gear backlash.
27) Remove the RH and LH side retainers.
28) Install the O-ring to left and right side retainers.
NOTE:
Use new O-rings.
29) Install the oil seal to the side retainer of both sides.
30) Align the arrow mark on the differential carrier with the arrow mark on the side retainer during installation.
31) Apply liquid gasket to the bolts indicated by arrows, and tighten the side retainer bolt.
Liquid gasket:
THREE BOND 1110B (Part No. K0879Y0020) or equivalent
Tightening torque:
10.5 Nm (1.1 kgf-m, 7.7 ft-lb)
32) Install the gasket and rear cover, and tighten the bolts to specified torque.
NOTE:
Use a new gasket.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
33) Install the air breather cap.
NOTE:
When installing the air breather cap, do not tap section (A). Be sure to tap section (B) to install.
34) Install the drain plug.
NOTE:
Use a new gasket.
Tightening torque:
60 Nm (6.1 kg-m, 44.3 ft-lb)
35) Install the oil temperature switch.
NOTE:
^ Install the oil temperature switch and adapter as a unit.
^ After installing the rear differential assembly to the vehicle, fill the gear oil, then use a new gasket, and tighten to the specified torque.