Assembly Inspection And Adjustment

• Drain the differential gear oil before inspection and adjustment. Refer to DIFFERENTIAL GEAR OIL .
• Remove and install the carrier cover as necessary for inspection and adjustment. Refer to "REMOVAL AND INSTALLATION ".

Total Preload Torque

1. Install the differential side shaft if necessary. Refer to "REMOVAL AND INSTALLATION ".
   CAUTION: The differential side shaft must be installed in order to measure total preload torque.
2. Rotate the drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
3. Rotate the drive pinion at least 20 times to check for smooth operation of the bearings.
4. Measure total preload torque using Tool.

   Tool number : ST3127S000 (J-25765-A) 

   Total preload torque: 

   Refer to "INSPECTION AND ADJUSTMENT "

   Fig 1: Measuring Total Preload Torque

   
   NOTE: Total preload torque = Drive pinion bearing preload torque + Side bearing preload torque
   • If the measured value is out of the specification, check and adjust each part. Adjust the drive pinion bearing preload torque first, then adjust the side bearing preload torque.

     If the total preload torque is greater than specification 

     On drive pinion bearings: Replace the collapsible spacer. 

     On side bearings: Use thinner side bearing adjusting washers by the same amount on each side.  Refer to "INSPECTION AND ADJUSTMENT ".

     If the total preload torque is less than specification 

     On drive pinion bearings: Tighten the drive pinion lock nut. 

     On side bearings: Use thicker side bearing adjusting washers by the same amount on each side.  Refer to "INSPECTION AND ADJUSTMENT ".

   CAUTION: Select a side bearing adjusting washer for right and left individually.

Drive Gear Runout

1. Fit a dial indicator to the drive gear back face.
2. Rotate the drive gear to measure runout.

   Runout limit:  Refer to "INSPECTION AND ADJUSTMENT "

   Fig 2: Measuring Drive Gear Runout

   
   • If the runout is outside of the limit, check the condition of the drive gear assembly. Foreign material may be caught between the drive gear and differential case, or the differential case or drive gear may be deformed.
   CAUTION: Replace drive gear and drive pinion as a set.

   Tooth Contact

   1. Apply red lead to the drive gear.
      NOTE: Apply red lead to both faces of three to four gears, at four locations evenly spaced on the drive gear.
      Fig 3: Applying Red Lead To Drive Gear

      
   2. Rotate the drive gear back and forth several times. Then check for correct drive pinion to drive gear tooth contact as shown.
      CAUTION: Check tooth contact on drive side and reverse side.
      Fig 4: Identifying Reverse And Drive Sides Of Drive Pinion Gear

      
      • If the tooth contact is improperly adjusted, adjust the drive pinion height (dimension X).
        Fig 5: Adjusting Pinion Height

        
        • If the tooth contact is near the face (face contact), or near the heel (heel contact), use a thicker drive pinion height adjusting washer to move drive pinion closer to the drive gear.

          Refer to "DISASSEMBLY AND ASSEMBLY ".

          Fig 6: Identifying Tooth Contact (Face And Heel Contacts)

          
        • If the tooth contact is near the flank (flank contact), or near the toe (toe contact), use a thinner drive pinion height adjusting washer to move the drive pinion farther from the drive gear. Refer to "INSPECTION AND ADJUSTMENT ".
          Fig 7: Identifying Tooth Contact (Flank And Toe Contacts)

          

Backlash

1. Fit a dial indicator to the drive gear face to measure the backlash.

   Backlash:  Refer to "INSPECTION AND ADJUSTMENT "

   Fig 8: Measuring Drive Pinion Backlash Using Dial Indicator

   
   • If the backlash is outside of the specification, change the thickness of the side bearing adjusting washers.

     If the backlash is greater than specification: 

     Make side bearing adjusting washer thicker on drive gear back side, and side bearing adjusting washer thinner on drive gear tooth side by the same amount. 

     Refer to "INSPECTION AND ADJUSTMENT ".

     If the backlash is less than specification: Make side bearing adjusting washer thinner on drive gear back side, and side bearing adjusting washer thicker on drive gear tooth side by the same amount. 

     Refer to "INSPECTION AND ADJUSTMENT ".

     CAUTION: Do not change the total thickness of side bearing adjusting washers as it will change the side bearing preload torque.

Companion Flange Runout

1. Rotate companion flange and check for runout on the companion flange face (inner side of the bolt holes) and companion flange inner side (socket diameter) using suitable tool.

   Runout limit:  Refer to "INSPECTION AND ADJUSTMENT "

   Fig 9: Checking Companion Flange Runout

   
2. If the runout is outside the runout limit, follow the procedure below to adjust.
   1. Rotate the companion flange on the drive pinion by 90°, 180° and 270° while checking for the position where the runout is minimum.
   2. If the runout is still outside of the runout limit after the companion flange has been rotated on the drive pinion, possible cause could be an assembly malfunction of drive pinion and drive pinion bearing or a malfunctioning drive pinion bearing.
   3. If the runout is still outside of the runout limit after repair of the assembly of drive pinion and drive pinion bearing or drive pinion bearing, replace the companion flange.