Part 2

ASSEMBLY AND ADJUSTMENT OF DRIVE PINION SHAFT




1. INSTALL NEW O-RING ONTO BEARING CAGE




2. INSTALL DRIVE PINION SHAFT INTO CASE
Slightly tap the cage into the case until the groove with the bore can be seen.

HINT: Drive in the bearing cage until the surface of the bearing cage passes through the groove with the bore.




3. INSTALL SNAP RING INTO CASE
a. Using SST, install the snap ring into the groove.

SST 09350-32014 (09351-32050)




b. Slightly tap the drive pinion to fit the snap ring into the groove.




4. INSTALL OIL SLINGER
Install the oil slinger, facing the lip outward.




5. INSTALL OUTER RACE
Using SST, drive the outer race into the case.

SST 09350-32014 (09351-32100, 09351-32140)




6. INSTALL NEW SPACER
Always use a new spacer.
Install the spacer with the small end first.




7. INSTALL COUNTER DRIVEN GEAR ONTO SHAFT
a. Place a bar at the drive pinion side and position the other end of the bar against a vise or such.




b. Drive the gear onto the shaft until the nut can be installed on the threads of the shaft.

NOTE: Be careful not to cause an impact to the transmission case.

SST 09350-32014 (09351-32140)

8. ADJUST DRIVE PINION PRELOAD




a. Coat the threads and surface of the nut with MP grease.
b. Using SST to hold the gear, tighten the nut.

Torque: 1.750 kg-cm (127 ft-lb. 172 N.m)

SST 09330-00021, 09350-32014 (09351-320321)




c. Turn the gear counterclockwise and clockwise several times.
d. Using a torque meter, measure the preload of the drive pinion.

Preload (at starting):

New bearing 10 - 16 kg-cm (8.7 - 13.9 in.-lb, 1.0 - 1.6 N.m)
Reused bearing 5 - 8 kg-cm (4.3 - 6.9 in.-lb, 0.5 - 0.8 N.m)

- If the preload is greater than specified, replace the bearing spacer.
- If the preload is less than specified, retighten the nut 130 kg-cm (9 ft-lb, 13 N.m) at a time until the specified 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 nut to reduce the preload.

Maximum torque: 2,950 kg-cm (213 ft-lb, 289 N.m)

e. If the preload is adjusted within specification, make a note of it.

ASSEMBLY OF DIFFERENTIAL




1. PLACE OUTER RACE AND SELECTED ADJUSTING SHIM ONTO RH SIDE BEARING




2. PLACE DIFFERENTIAL CASE INTO CASE
Be sure to install the adjusting shim into place.

3. INSTALL LH BEARING RETAINER




a. Install a new O-ring.
b. While holding the differential case centered with the retainer, tap in the retainer.




c. Clean the threads of the bolts and case with white gasoline.
d. Coat the threads of the bolts with sealant.

Sealant: Part No.08833-00070, THREE BOND 1324 or equivalent

e. Temporarily tighten the bolts evenly and gradually while turning the ring gear.




4. INSTALL RH SIDE BEARING CAP
Tighten the bolts evenly and gradually while turning the ring gear.

Torque: 500 kg-cm (36 ft-lb, 49 N.m)




5. TIGHTEN LH BEARING RETAINER

Torque: 195 kg-cm (14 ft-lb, 19 N.m)




6. MEASURE TOTAL PRELOAD
Using a torque meter, measure the total preload of the drive pinion shaft.

Total preload (at starting):

Add drive pinion preload.

New bearing 2.6 - 4.3 kg-cm (2.3 - 3.7 in.-lb, 0.3 - 0.4 N.m)
Reused bearing 1.3 - 2.2 kg-cm (1.1 - 1.9 in-lb, 0.1 - 0.2 N.m)

If the preload is not within specification, disassemble and readjust.




7. STAKE COUNTER DRIVEN GEAR NUT




8. INSTALL DRIVE PINION CAP




9. INSTALL CARRIER COVER
a. Clean the threads of the bolts and case with white gasoline.
b. Coat the threads of the bolts with sealant.

Sealant: Part No.08833-00070, THREE BOND 1324 or equivalent

c. Install the carrier cover over the gasket.

Torque: 250 kg-cm (18 ft-lb, 25 N.m)