Disassembly and Assembly: Assembly

Drive Pinion Assembly

1. Install drive pinion rear bearing outer race using Tools.

   Tool number (A): ST30901000 (-) 

   (B): KV40105230 (-) 

   Fig 1: Installing Drive Pinion Rear Bearing Outer Race Using Tools

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2. Install drive pinion front bearing outer race using Tools.

   Tool number (A): ST35271000 (-) 

   (B): KV40104810 (-) 

   Fig 2: Installing Drive Pinion Front Bearing Outer Race Using Tools

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3. Select drive pinion height adjusting washer. Refer to "INSPECTION AND ADJUSTMENT ".
4. Install the selected drive pinion height adjusting washer to the drive pinion. Press the drive pinion rear bearing inner race to it using Tool.

   Tool number: - C-4040 

   Fig 3: Installing Selected Drive Pinion Height Adjusting Washer

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   CAUTION: Do not reuse drive pinion rear bearing inner race.
5. Install the collapsible spacer to the drive pinion.
   CAUTION: Do not reuse collapsible spacer.
6. Apply differential gear oil to the drive pinion rear bearing, and install the drive pinion assembly to the gear carrier.
7. Apply differential gear oil to the drive pinion front bearing, and install the drive pinion front bearing inner race to the drive pinion assembly.
   CAUTION: Do not reuse drive pinion front bearing inner race.
   Fig 4: Identifying Collapsible Spacer, Pinion Rear Bearing Inner Race And Drive Pinion

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8. Apply multi-purpose grease to the lips of the new front oil seal. Then drive the new front oil seal in evenly using Tools.

   Tool number (A): KV38100500 (J-25273) 

   (B): KV38102200 (-) 

   Fig 5: Installing Front Oil Seal Using Tools

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   CAUTION:

   • Do not reuse front oil seal.
   • Do not incline the new front oil seal when installing.
   • Apply multi-purpose grease to the lips of the new front oil seal.
9. Install the companion flange to the drive pinion while aligning the matching marks. Tap the companion flange until fully seated using suitable tool.
   Fig 6: Tapping Companion Flange Onto Drive Pinion Using Tool

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10. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut. Then adjust the drive pinion lock nut tightening torque using suitable tool (A), and check the drive pinion bearing preload torque using Tool (B).

    Tool number (B): ST3127S000 (J-25765-A) 

    Drive pinion bearing preload torque Refer to  "INSPECTION AND ADJUSTMENT "

    Fig 7: Adjusting Drive Pinion Lock Nut Tightening Torque Using Tool

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    CAUTION:

    • Do not reuse drive pinion lock nut.
    • Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut.
    • Adjust the drive pinion lock nut tightening torque to the lower limit first. Do not exceed the drive pinion lock nut specified torque. Refer to "EXPLODED VIEW ".
    • If the drive pinion bearing 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 drive pinion bearing preload torque.
    • After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.
11. Check companion flange runout. Refer to "INSPECTION AND ADJUSTMENT ".
12. Install the differential case assembly. Refer to "EXPLODED VIEW ".

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.
   Fig 8: Installing Side Gear Thrust Washers

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2. Install the side gears and side gear thrust washers into the differential case.
3. Install the pinion mate thrust washers to the two pinion mate gears. Then install the pinion mate gears with the pinion mate thrust washers by aligning them in diagonally opposite positions and rotating them into the differential case.
   Fig 9: Installing Side Gears And Side Gear Thrust Washers

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4. Install the pinion mate shaft and align the lock pin hole on the pinion mate shaft with the lock pin hole on the differential case.
5. Measure the side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to "INSPECTION AND ADJUSTMENT ".
   Fig 10: Locating Differential Case

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6. Drive a new lock pin into the pinion mate shaft until it is flush with the differential case using suitable tool.
   CAUTION: Do not reuse lock pin.
   Fig 11: Installing Lock Pin Into Pinion Mate Shaft

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7. Align the matching mark of the differential case with the mark of the drive gear, then place the drive gear onto the differential case.
   Fig 12: Identifying Matching Mark Of Differential Case And Drive Gear

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8. Install and tighten the new drive gear bolts to the specified torque. Refer to "EXPLODED VIEW ".
   CAUTION:

   • Make sure the drive gear back and threaded holes are clean.
   • Do not reuse drive gear bolts.
   • Tighten new drive gear bolts in a crisscross pattern.
     Fig 13: Identifying Drive Gear Bolts

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9. Press the new side bearing inner races to the differential case using Tools.

   Tool number (A): KV38100300 (J-25523) 

   (B): ST33081000 (-) 

   Fig 14: Pressing Side Bearing Inner Races Into Differential Case Using Tools

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   CAUTION: Do not reuse side bearing inner races.
10. Install side bearing adjusters into gear carrier.
11. Apply differential gear oil to the side bearings, and install the differential case assembly with the side bearing outer races into the gear carrier.
    CAUTION: Do not reuse side bearing outer race when replacing side bearing inner race (replace as a set).
    Fig 15: Installing Differential Case Assembly Into Gear Carrier

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12. Install the side bearing caps with the matching marks aligned.
    NOTE: Do not tighten at this step. This allows further tightening of side bearing adjusters.
    Fig 16: Identifying Matching Mark On Bearing Cap And Gear Carrier

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13. Tighten each side bearing adjuster alternately turning drive gear.
    Fig 17: Tightening Side Bearing Adjuster

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14. Check and adjust tooth contact, backlash, drive gear runout and total preload torque. Refer to "INSPECTION AND ADJUSTMENT ".

    Recheck above items.

    • After adjusting tooth contact and backlash secure side bearing adjuster with screws and tighten side bearing cap bolt to the specified torque. Refer to "EXPLODED VIEW ".
      Fig 18: Tightening Side Bearing Cap Bolt

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15. Apply multi-purpose grease to the lips of the new side oil seal. Then drive the new side oil seal in evenly to the gear carrier using suitable tool.
    CAUTION:

    • Do not reuse side oil seal.
    • Do not incline the new side oil seal when installing.
    • Apply multi-purpose grease to the lips of the new side oil seal.
16. Install the extension tube with a new O-ring.
    CAUTION:

    • Do not reuse O-ring.
    • If the extension tube is being replaced, install a new differential side shaft bearing.
      Fig 19: O-Ring, Extension Tube And Gear Carrier With Torque Specifications

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17. Apply 3 mm (0.12 in) bead of sealant to the mating surface of the carrier cover as shown.
    • Use Genuine Silicone RTV or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
      CAUTION: Remove any old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to the application and mating surfaces.
18. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Refer to "EXPLODED VIEW ".
19. Install differential side shaft and differential side flange.
    Fig 20: Identifying Carrier Cover Sealant Applying Surface

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