Assembly Of Differential

1. TEMPORARILY ADJUST DRIVE PINION PRELOAD

(a) Install the following parts.

• Front bearing

NOTE: Assemble the spacer, oil slinger and oil seal after adjusting the gear contact pattern.

SST

(b) Install the companion flange with SST.

Coat the threads of the nut with MP grease. SST 09557-22022

(c) Adjust the drive pinion preload by tightening the companion flange nut.

Using SST to hold the flange, tighten the nut. SST 09330 00021

CAUTION: As there is no spacer, tighten a little at a time, being careful not to overtighten it.

(d) Using a torque wrench, measure the preload. Preload:

New bearing 12 - 19 kg-cm

(10.4 - 16.5 in.-lb, 1.2 - 1.9 N m) Reused bearing 6 — 10 kg-cm

2. INSTALL DIFFERENTIAL CASE IN CARRIER

(a) Place the bearing outer races on their respective bear ings. Make sure the left and right outer races are not interchanged.

(b) Install the differential case in the carrier.

3. ADJUST RING GEAR BACKLASH

(a) Install only the plate washer on the ring gear back side.

NOTE: Insure that the ring gear has a backlash.

(b) Snug down the washer and bearing by tapping on the ring gear with a plastic hammer.

(c) Hold the side bearing boss on the teeth surface of the ring gear and measure the backlash.

(d) Select a ring gear back plate washer using the backlash as reference. (See page RA-32)

Side Washer

(e) Select a ring gear teeth side washer of a thickness which eliminates any clearance between the outer race and case.

(f) Remove the plate washers and differential case.

(g) Install the plate washer into the lower part of the carrier.

(h) Place the other plate washer onto the differential case together with the outer race, and install the differential case with the outer race into the carrier.

(i) Using a plastic hammer, snug down the washer and bearing by tapping the ring gear.

(j) Using a dial indicator, measure the ring gear backlash. Backlash: 0.13 - 0.18 mm (0.0051 - 0,0071 in.)

Side Wather

Side

Washer^

raoow

raoow

Side Wather

Side

Washer^

Thickness

Thickness

2.57 - 2.59 <0.1012 - 0.1020) 2.60 - 2.62 <0.1024 - 0.1031) 2.63 - 2.65 <0.1035 - 0.1043) 2.66 - 2.68 <0.1047 - 0.1055) 2.69 - 2.71 <0.1059 - 0.1067) 2.72 - 2.74 (0.1071 - 0.1079) 2.75-2.77 (0.1083 -0.1091) 2.78 - 2.80(0.1094 - 0.1102) 2.81 - 2.83 (0.1106-0.1114) 2.84-2.86(0.1118-0.1126) 2.87-2.89 (0.1130-0.1138) 2.90-2.92 <0.1142-0.1150)

2.93 — 2.95 <0.1154-0.1161) 2.96-2.98 <0.1165-0.1173) 2.99-3.01 <0.1177-0.11855 3.02-3.04 <0.1189-0.1197) 3.05-3.07 <0.1201 -0.1209) 3.08- 3.10 (0.1213 -0.12200 3.11 -3.13 (0.1224-0.1232) 3.14- 3.16 (0.1236-0.1244! 3.17-3.19(0.1248-0.1256) 3.20 - 3.22 (0.1260 - 0.1268) 3.23 -3.25 (0.1272 -0.128W

(d) Recheck the ring gear backlash.

(e) If not within standard, adjust by either increasing* decreasing the washers on both sides by equal amount

NOTE: The backlash will change about 0.02 mm (0.0006 in.) with 0.03 mm (0.0012 in.) alteration of the side washer.

Washer thickness mm fa

4. ADJUST SIDE BEARING PRELOAD

(a) After adjustment with the backlash as reference, remove the ring gear teeth plate washer and measure the thickness.

(k) If not within specification, adjust by either increasing or decreasing the number of washers on both sides by an equal amount.

NOTE: There should be no clearance between the ptae washer and case.

Insure that there is ring gear backlash.

NOTE: Select a washer which can be pressed in the way by finger.

(c) Using a plastic hammer, tap in the side washer.

Install a new washer of 0.06 — 0.09 mm 0.0035 in.) thicker than the washer removed.

*AOOO

5. INSTALL SIDE BEARING CAPS

Align the marks on the cap and carrier. Torque: 800 kg-cm (58 ft-lb, 78 N m)

6. MEASURE TOTAL PRELOAD

Using a torque wrench, measure the total preload.

Total preload: In addition to drive pinion preload 4-6 kg-cm (3.5 - 5.2 ¡n.-lb, 0.4 - 0.6 N-m)

Heel Contact

Preload Drive Pinion

Select an adjusting shim that will bring the drive pinion clo$er tojthe ring gear.

Toe Contact

Proper Contact

Face Contact

Flank Contact

Select an adjusting shim that will bring the drive pinion clo$er tojthe ring gear.

Proper Contact

7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

(a) Coat 3 or 4 teeth at three different positions on the ring gear with red lead.

(b) Hold the companion flange firmly and rotate the ring gear in both directions.

(c) Inspect the tooth pattern.

Select an adjusting shim that will shift the drive pinion away from the ring gear.

Heel Contact

Face Contact

Toe Contact

Flank Contact

Thickness

Washer thickness mm (inj

8. REMOVE COMPANION FLANGE (See step 10 on page RA-24)

9. REMOVE FRONT BEARING AND BEARING SPACER (See step 12 on page RA-25)

10. INSTALL NEW BEARING SPACER AND FRONT BEARING

(a) Install a new bearing spacer on the shaft.

(b) Install the front bearing on the shaft.

11. INSTALL OIL SLINGER AND NEW OIL SEAL

(a) Install the oil slinger facing as shown.

(b) Using SST, drive in a new oil seal. SST 09316-60010

(c) Apply MP grease to the oil seal lip.

12. INSTALL COMPANION FLANGE

(a) Using SST, install the companion flange on the shaft. SST 09557-22022

If the teeth are not contacting properly, use the following chart to select a proper washer for correction.

Washer thickness mm (inj

Thickness

Thickness

(0.0882) (0.0894) (0.0906) (0.0917) (0.0929) (0.0941) (0.0953) (0.0965) (0.0976)

(b) Coat the threads of a new nut with MP grease.

(c) Using SST to hold the flange, tighten the nut. SST 09330-00021

New bearing Reused bearing

13. CHECK FRONT BEARING PRELOAD

Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

Preload:

(a) If preload is greater than specification, replace the bearing spacer.

(b) If the preload is less than specification, retighten the nut 130 kg-cm (9 ft-lb, 13 N-m) at a time until the specif ied preload is reached.

If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the pinion nut to reduce the preload.

Supra Diff Seals

14. CHECK RUNOUT OF COMPANION FLANGE

Using a dial indicator, measure the lateral and radial runout of the companion flange.

If the runout is greater than the maximum, inspect the bearings.

Maximum lateral runout: 0.10 mm (0.0039 in.) Maximum radial runout: 0.10 mm (0.0039 in.)

15. STAKE DRIVE PINION NUT

16. INSTALL SIDE GEAR SHAFT OIL SEAL

(a) Coat the oil seal lip with MP grease No. 2.

(b) Using SST, drive in the oil seal until it is flush with the carrier end surface.

SST 09550-22011 (09550-00020 and 09550 00030)

AA00Ô7

17. INSTALL SIDE GEAR SHAFT

(a) Before installing the shaft, replace the snap ring.

(b) Using a plastic hammer, drive in the side gear shaft until it contacts the pinion shaft.

NOTE: As the LSD cannot be checked visually, check that the shaft is fully inserted by confirming the sound it makes when it is tapped.

BA0038

BA0038

18. MEASURE SIDE GEAR SHAFT RUNOUT

If the runout is greater than the maximum, replace the side gear shaft.

19. INSTALL DIFFERENTIAL CARRIER COVER

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