PROPELLER SHAFT & GI

DIFFERENTIAL CARRIER
MA

SECTION PD EM

LC

EC

CONTENTS FE

PREPARATION................................................................3 INSPECTION..................................................................23
CL
Special Service Tools ..................................................3 Ring Gear and Drive Pinion ......................................23
NOISE, VIBRATION AND HARSHNESS (NVH) Differential Case Assembly........................................23
TROUBLESHOOTING .....................................................7 Bearing.......................................................................23 MT
NVH Troubleshooting Chart.........................................7 ADJUSTMENT ...............................................................24
Side Bearing Preload.................................................24
PROPELLER SHAFT Pinion Gear Height and Pinion Bearing Preload.......25 AT
Pinion Bearing Preload Washer Selection............27
PROPELLER SHAFT ......................................................8 Pinion Height Adjusting Washer Selection............28
On-vehicle Service.......................................................9 Tooth Contact.............................................................30 TF
Removal and Installation .............................................9 ASSEMBLY....................................................................31
Inspection.....................................................................9 Differential Side Shaft................................................31
Differential Case ........................................................31 PD
Disassembly...............................................................10
Assembly ...................................................................11 Final Drive Housing ...................................................33
FA
FINAL DRIVE H233B

ON-VEHICLE SERVICE ................................................13 REAR FINAL DRIVE .....................................................37 RA

Front Oil Seal Replacement ......................................13 DISASSEMBLY..............................................................38
(Front final drive: Model R200A) ......................13 Pre-inspection ............................................................38
Differential Carrier......................................................38 BR
(Rear final drive: Model H233B).......................13
REMOVAL AND INSTALLATION (Front final Differential Case ........................................................40
drive)..............................................................................15 INSPECTION..................................................................42
Ring Gear and Drive Pinion ......................................42
ST
Removal.....................................................................15
Installation..................................................................15 Differential Case Assembly........................................42
REMOVAL AND INSTALLATION (Rear final drive) ....16 Bearing.......................................................................42 RS
Removal.....................................................................16 LIMITED SLIP DIFFERENTIAL.....................................43
Installation..................................................................16 Preparation for Disassembly .....................................43
Checking Differential Torque .................................43 BT
Disassembly...............................................................43
R200A
Inspection...................................................................44
Contact Surfaces...................................................44 HA
FRONT FINAL DRIVE ...................................................17 Disc And Plate.......................................................44
DISASSEMBLY..............................................................18 Adjustment .................................................................45
Pre-inspection ............................................................18 Friction Disc And Friction Plate End Play.............45 EL
Final Drive Housing ...................................................18 Assembly ...................................................................46
Differential Case ........................................................21 ADJUSTMENT ...............................................................49
Differential Side Shaft................................................21 Pinion Gear Height ....................................................49
IDX
 CONTENTS (Cont’d.)
Pinion Height Adjusting Washer Selection............50 General Specifications ..........................................58
Tooth Contact.............................................................52 Inspection And Adjustment (R200A) .....................58
ASSEMBLY....................................................................53 Ring gear runout...............................................58
Differential Case ........................................................53 Side gear adjustment .......................................58
Differential Carrier......................................................54 Side bearing adjustment...................................58
SERVICE DATA AND SPECIFICATIONS (SDS) ..........57 Inspection And Adjustment (H233B) .....................59
Propeller Shaft ...........................................................57 Ring gear runout...............................................59
General Specifications ..........................................57 — Additional service for LSD model —
Inspection And Adjustment....................................57 Differential torque adjustment...........................59
Service data......................................................57 Drive pinion height adjustment.........................60
Snap ring ..........................................................57 Drive pinion preload adjustment.......................60
Final Drive..................................................................58 Total preload adjustment ..................................60

PD-2
 PREPARATION

Special Service Tools GI

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Unit application MA
(Kent-Moore No.) Description
Tool name R200A H233B

ST3127S000 Measuring pinion bearing preload and EM

(See J25765-A) total preload
Preload gauge
s1 GG91030000 LC
(J25765)
Torque wrench
s2 HT62940000
X X EC
( — )
Socket adapter
s3 HT62900000 FE
( — )
Socket adapter NT124
CL
KV38100800 Mounting final drive
(J34310, J25604-01) (To use, make a new hole.)
Differential attachment
X — MT

NT119 a: 152 mm (5.98 in)

AT
ST06340000 Mounting final drive
(J24310, J34310)
Differential attachment
— X TF

NT140
PD
ST32580000 Adjusting side bearing preload and
(J34312) backlash (ring gear-drive pinion)
Differential side bearing FA
adjusting nut wrench — X

NT141
RA
ST38060002 Removing and installing propeller shaft
(J34311) lock nut, and drive pinion lock nut BR
Drive pinion flange X —
wrench

NT113
ST
KV38104700 Removing and installing propeller shaft
(J34311) lock nut, and drive pinion lock nut RS
Drive pinion flange — X
wrench

NT113 BT
ST3090S000 Removing and installing drive pinion
( — ) rear inner cone
HA
Drive pinion rear inner
race puller set
s 1 ST30031000
X X EL
(J22912-01)
Puller
s 2 ST30901000 a: 79 mm (3.11 in) dia.
IDX
(J26010-01) b: 45 mm (1.77 in) dia.
Base NT527 c: 35 mm (1.38 in) dia.

PD-3
 PREPARATION
Special Service Tools (Cont’d)
Tool number Unit application
(Kent-Moore No.) Description
Tool name R200A H233B

ST3306S001 Removing and installing differential side

Differential side bearing bearing inner cone
puller set
s1 ST33051001
(J22888-20) X X
Body
s2 ST33061000
(J8107-2) a: 28.5 mm (1.122 in) dia.
Adapter NT072 b: 38 mm (1.50 in) dia.
KV38100300 Installing side bearing inner cone
(J25523)
Differential side bearing
drift X —
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
NT085 c: 32 mm (1.26 in) dia.
ST33190000 Installing side bearing inner cone
(J25523)
Differential side bearing
drift — X
a: 52 mm (2.05 in) dia.
b: 45.5 mm (1.791 in) dia.
NT085 c: 34 mm (1.34 in) dia.
ST33081000 Installing side bearing inner cone
( — )
Side bearing puller
adapter — X

a: 43 mm (1.69 in) dia.

NT431 b: 33.5 mm (1.319 in) dia.
KV38100600 Installing side bearing spacer
(J25267)
Side bearing spacer drift
X —

a: 8 mm (0.31 in)
NT528 b: R42.5 mm (1.673 in)
ST30611000 Installing pinion rear
(J25742-1) bearing outer race
Drift (Use with ST30621000 or ST30613000) X X

NT090

ST30621000 Installing pinion rear bearing outer race

(J25742-5) (Use with ST30611000)
Drift
X X

a: 79 mm (3.11 in) dia.

NT073 b: 59 mm (2.32 in) dia.
ST30613000 Installing pinion front bearing outer race
(J25742-3) (Use with ST30611000)
Drift
X X

a: 72 mm (2.83 in) dia.

NT073 b: 48 mm (1.89 in) dia.

PD-4
 PREPARATION
Special Service Tools (Cont’d)
GI
Tool number Unit application
(Kent-Moore No.) Description
Tool name R200A H233B
MA
KV381025S0 Installing front oil seal
( — )
Oil seal fitting tool EM
s 1 ST30720000
(J25405) — X
Drift bar a: 77 mm (3.03 in) dia. LC
s 2 KV38102510 b: 55 mm (2.17 in) dia.
( — ) c: 71 mm (2.80 in) dia.
Drift NT525 d: 65 mm (2.56 in) dia. EC
KV38100500 Installing front oil seal
(J25273)
Gear carrier front oil seal FE
X —
drift
a: 85 mm (3.35 in) dia.
NT115 b: 60 mm (2.36 in) dia. CL
KV38100200 Installing side oil seal
(J26233)
Gear carrier side oil seal MT
X —
drift

NT120 AT
(J34309) Adjusting bearing pre-load and gear
Differential shim height
selector TF

PD
X X

FA

NT134
RA
(J25269-4) Selecting pinion height adjusting washer
Side bearing discs
(2 Req’d)
X — BR

NT136
ST
(J25269-18) Selecting pinion height adjusting washer
Side bearing discs
(2 Req’d) — X RS

NT135

(J8129) Measuring carrier turning torque

BT
Spring gauge

X X HA

NT127
EL

IDX

PD-5
 PREPARATION
Special Service Tools (Cont’d)
Tool number Unit application
(Kent-Moore No.) Description
Tool name R200A H233B

KV381052S0 Checking differential torque on limited

( — ) slip differential
Rear axle shaft dummy
s 1 KV38105210
( — ) — X
Torque wrench side
s 2 KV38105220
( — )
Vice side NT142

PD-6
 Symptom

X : Applicable
Reference page

Possible cause and

SHAFT
SUSPECTED PARTS

PROPELLER

DIFFERENTIAL
Noise
Noise
Shake
Vibration
X
X
Uneven rotation torque —

X
X
X
Center bearing improper installlation PD-8, 11

X
X
Excessive center bearing axial end play —

X
X
Center bearing mounting (insulator) cracks, damage or deterioration —

X
X
X
Excessive joint angle —

PD-7
X
X
Rotation imbalance PD-9

X
X
Excessive runout PD-9

X
Rough gear tooth PD-23, 42

X
Improper gear contact PD-30, 52

X
Tooth surfaces worn PD-23, 42

X
Incorrect backlash PD-35, 56

X
Companion flange excessive runout —
NVH Troubleshooting Chart

X
Improper gear oil Refer to MA section

X
PROPELLER SHAFT Refer to PROPELLER SHAFT in this chart

X
DIFFERENTIAL Refer to DIFFERENTIAL in this chart

X
X
X
X
DRIVE SHAFT NVH in FA section

X
X
X
X
AXLE AND SUSPENSION NVH in FA, RA section

X
X
X
X
TIRES NVH in FA section
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

X
X
X
ROAD WHEEL NVH in FA section

X
X
X
BRAKES NVH in BR section
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

X
X
X
X STEERING NVH in ST section
GI

TF
AT

EL
FE

ST
FA

BT
CL
LC

RS
EC

RA

HA
BR
MT

PD
EM
MA

IDX
 PROPELLER SHAFT PROPELLER SHAFT

Front propeller shaft (Model 2F1310)

APD025

Rear propeller shaft (Model 3S1310)

WPD017

PD-8
 PROPELLER SHAFT PROPELLER SHAFT

On-vehicle Service GI
PROPELLER SHAFT VIBRATION
If vibration is present at high speed, inspect propeller shaft runout MA
first.
1. Raise rear end of vehicle until wheels are clear of the ground.
2. Measure propeller shaft runout at several points along propel- EM
ler shaft by rotating final drive companion flange using hands.
3. If runout exceeds specifications, disconnect propeller shaft at
final drive companion flange. Rotate companion flange 180 LC
SPD728
degrees, then reconnect propeller shaft.
Runout limit: 0.6 mm (0.024 in)
4. Check runout again. If runout still exceeds the limit, replace EC
propeller shaft assembly.
5. Perform road test.
FE
APPEARANCE CHECKING
● Inspect propeller shaft tube surface for dents or cracks and
replace as necessary. CL
● Check center bearing for noise or damage and replace as
necessary.
MT
SPD102

Removal and Installation AT

1. Place matching marks on flanges, then separate propeller
shaft from final drive. TF

PD

FA
SPD103

2. Remove propeller shaft. RA

● Insert plug into rear oil seal after removing rear propeller
shaft.
BR

ST

RS
SPD359
BT
Inspection
● Inspect propeller shaft runout. If runout exceeds the limit,
replace propeller shaft assembly. HA
Runout limit: 0.6 mm (0.024 in)

EL

IDX
SPD106

PD-9
 PROPELLER SHAFT PROPELLER SHAFT
Inspection (Cont’d)
● Inspect journal axial play.
If play exceeds the limit, replace propeller shaft assembly.
Journal axial play:
0.02 mm (0.0008 in) or less

SPD874

Disassembly
CENTER BEARING
1. Place matching marks on flanges, then separate 2nd tube from
1st tube.

SPD109

2. Place matching marks on the flange and shaft.

SPD110

3. Remove locking nut using Tool.

Tool number:
ST38060002 (J34311)
4. Remove companion flange using puller.

SPD170A

5. Remove center bearing using Tool and press.

Tool number: ST30031000 (J22912-01)

SPD113

PD-10
 PROPELLER SHAFT PROPELLER SHAFT
Disassembly (Cont’d)
JOURNAL GI
NOTE:
1. Place matching marks on propeller shaft and flange or yoke. MA

EM

LC
SPD128

2. Remove snap ring. EC

FE

CL

MT
APD011

3. Remove pushed out journal bearing by lightly tapping yoke AT

with a hammer, taking care not to damage journal and yoke
hole.
TF

PD

FA
SPD732

4. Remove bearing at opposite side in above operation. RA

Put marks on disassembled parts so that they can be
reinstalled in their original positions.
BR

ST

RS
SPD131
BT
Assembly
CENTER BEARING
HA
● When installing center bearing, position the ‘‘F’’ mark on cen-
ter bearing toward front of vehicle.
● Apply a coat of multi-purpose lithium grease containing EL
molybdenum disulfide to the end face of the center bearing
and both sides of the washer.
IDX
SPD114

PD-11
 PROPELLER SHAFT PROPELLER SHAFT
Assembly (Cont’d)
● Stake the nut. Always use new one.
● Align match marks when assembling tubes.

SPD117

JOURNAL
1. Assemble journal bearing. Apply recommended multi-purpose
grease on bearing inner surface.
When assembling, be careful that needle bearing does not fall
down.

SPD133

2. Select snap ring that will provide specified play in axial direction
of journal, and install them.
Refer to SDS, PD-57.
Select snap rings with a difference in thickness at both sides
within 0.06 mm (0.0024 in).

APD012

3. Adjust thrust clearance between bearing and snap ring to zero

by tapping yoke.

SPD732

4. Check to see that journal moves smoothly and check for axial
play.
Axial play: 0.02 mm (0.0008 in) or less

SPD874

PD-12
 ON-VEHICLE SERVICE FINAL DRIVE

Front Oil Seal Replacement GI

(Front final drive: Model R200A)
1. Remove front propeller shaft.
2. Loosen drive pinion nut. MA
Tool number: ST38060002 (J34311)
EM

LC
SPD733

3. Remove companion flange. EC

FE

CL

MT
SPD734

4. Remove front oil seal. AT

TF

PD

FA
SPD735

5. Apply multi-purpose grease to cavity at sealing lips of oil seal. RA

Press front oil seal into carrier.
Tool number:
KV38100500 (J25273) BR
6. Install companion flange and drive pinion nut.
7. Install propeller shaft.
ST

RS
SPD736
BT
(Rear final drive: Model H233B)
1. Remove rear propeller shaft.
2. Loosen drive pinion nut. HA
Tool number: KV38104700 (J34311)

EL

IDX
PD237

PD-13
 ON-VEHICLE SERVICE FINAL DRIVE
Front Oil Seal Replacement (Cont’d)
3. Remove companion flange.

SPD737

4. Remove front oil seal.

SPD738

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.

Press front oil seal into carrier.
Tool number:
ST30720000 (J25405)
KV38102510 ( — )
6. Install companion flange and drive pinion nut.
7. Install rear propeller shaft.

SPD739

PD-14
REMOVAL AND INSTALLATION (Front final drive) FINAL DRIVE

Removal GI
1. Remove front propeller shaft.
2. Separate drive shaft from front final drive. Refer to FA section MA
[‘‘Drive Shaft’’, ‘‘FRONT AXLE (4WD)’’].
3. Remove engine mounting bolts and raise up engine.
4. Remove front final drive together with differential mounting EM
member.

LC
SPD741

Installation EC
1. Install front final drive assembly together with differential
mounting member. FE

CL

MT
SPD742

2. Tighten front final drive securing bolts and nuts by following the AT
procedure to prevent drive train vibration.
a. Temporarily tighten nut s A .
b. Temporarily tighten nut s B . TF
c. Tighten bolt s C to the torque of 68 to 87 Nzm (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
d. Tighten bolt s D to the torque of 68 to 87 Nzm (6.9 to 8.9 kg-m, PD
50 to 64 ft-lb).
e. Tighten nut s A to the torque of 68 to 87 Nzm (6.9 to 8.9 kg-m,
50 to 64 ft-lb). FA
f. Tighten nut s B to the torque of 68 to 87 Nzm (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
g. Tighten nut s E to the torque of 68 to 87 Nzm (6.9 to 8.9 kg-m, RA
50 to 64 ft-lb).
3. Install drive shaft. Refer to FA section [‘‘Drive Shaft’’, ‘‘FRONT
AXLE (4WD)’’]. BR
4. Install front propeller shaft.

ST

RS
SPD743
BT

HA

EL

IDX

PD-15
REMOVAL AND INSTALLATION (Rear final drive) FINAL DRIVE

Removal
● Remove propeller shaft.
Plug front end of transfer.
● Remove axle shaft.
Refer to RA section (‘‘REAR AXLE’’).
CAUTION:
● Be careful not to damage spline, sleeve yoke and front oil
seal when removing propeller shaft.
● Before removing the final drive assembly or rear axle
assembly, disconnect the ABS sensor harness connector
from the assembly and move it away from the final drive/
rear axle assembly area. Failure to do so may result in the
sensor wires being damaged and the sensor becoming
inoperative.

Installation
● Fill final drive with recommended gear oil.

SPD123

PD-16
FRONT FINAL DRIVE R200A

GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

APD020

PD-17
 DISASSEMBLY R200A

Pre-inspection
Before disassembling final drive, perform the following inspection.
● Total preload
1) Turn drive pinion in both directions several times to set bear-
ing rollers.
2) Check total preload with Tool.
Tool number: ST3127S000 (J25765-A)
Total preload:
1.4 - 1.7 Nzm (14 - 17 kg-cm, 12 - 15 in-lb)

SPD664

● Ring gear to drive pinion backlash

Check backlash of ring gear with a dial indicator at several
points.
Ring gear-to-drive pinion backlash:
0.10 - 0.15 mm (0.0039 - 0.0059 in)

SPD513

● Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit:
0.05 mm (0.0020 in)
● Tooth contact
Check tooth contact. Refer to ADJUSTMENT (PD-30).

SPD524

● Side gear to pinion mate gear backlash

Using a feeler gauge, measure clearance between side gear
thrust washer and differential case.
Clearance between side gear thrust washer
and differential case:
Less than 0.15 mm (0.0059 in)

SPD665

Final Drive Housing

1. Using three spacers [20 mm (0.79 in)], mount final drive
assembly on Tool.
Tool number:
KV38100800 (J34310, J25604-01)

SPD666

PD-18
 DISASSEMBLY R200A
Final Drive Housing (Cont’d)
2. Remove differential side shaft assembly. GI

MA

EM

LC
SPD644

3. Remove differential side flange. EC

FE

CL

MT
SPD667

4. Put match marks on one side of side bearing cap with paint or AT
punch to ensure that it is replaced in proper position during
reassembly.
Bearing caps are line-bored during manufacture and should TF
be put back in their original places.
PD

FA
SPD526

5. Remove side bearing caps. RA

BR

ST

RS
PD343

6. Remove differential case assembly with a pry bar.

BT

HA

EL

IDX
SPD668

PD-19
 DISASSEMBLY R200A
Final Drive Housing (Cont’d)
Be careful to keep the side bearing outer races together with
their respective inner cones — don’t mix them up.
CAUTION:
Side bearing spacer is placed on either the left or right
depending upon final drive gear ratio. It should be labeled so
that it may be replaced correctly.

SPD527

7. Loosen drive pinion nut.

Tool number: ST38060002 (J34311)
8. Remove companion flange with puller.

SPD171A

9. Take out drive pinion together with rear bearing inner cone,
drive pinion bearing spacer and pinion bearing adjusting
washer.
10. Remove front oil seal and pinion front bearing inner cone.

SPD670

11. Remove pinion bearing outer races with a brass drift.

PD349

12. Remove pinion rear bearing inner cone and drive pinion height
adjusting washer.
Tool number: ST30031000 (J22912-01)

SPD209

PD-20
 DISASSEMBLY R200A

Differential Case GI
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in grooves. MA
Tool number:
sA ST33051001 (J22888-20)
sB ST33061000 (J8107-2) EM

LC
SPD207A

Be careful not to confuse the right and left hand parts. EC

Keep bearing and bearing race for each side together.
FE

CL

MT
SPD022

2. Loosen ring gear bolts in a criss-cross pattern. AT

3. Tap ring gear off the differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.
TF

PD

FA
SPD024

4. Punch off pinion mate shaft lock pin from ring gear side. RA

BR

ST

RS
SPD025
BT
Differential Side Shaft
1. Cut collar with cold chisel. Be careful not to damage differen-
tial side shaft. HA

EL

IDX
SPD236A

PD-21
 DISASSEMBLY R200A
Differential Side Shaft (Cont’d)
2. Reinstall differential side shaft into extension tube and secure
with bolts. Remove rear axle bearing by drawing out differen-
tial side shaft from rear axle bearing with puller.

SPD672

3. Remove grease seal and oil seal.

SPD647

SPD781

PD-22
 INSPECTION R200A

Ring Gear and Drive Pinion GI

Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive pinion MA
as a set (hypoid gear set).

EM

LC

Differential Case Assembly EC

Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft and thrust washers. FE

CL

MT
SPD097AA

Bearing AT
1. Thoroughly clean bearing.
2. Check bearing for wear, scratches, pitting or flaking. TF
Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner cone as a set.
PD

FA
SPD715

RA

BR

ST

RS

BT

HA

EL

IDX

PD-23
 ADJUSTMENT R200A

For quiet and reliable final drive operation, the following five adjust-
ments must be made correctly:
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload
4. Ring gear-to-pinion backlash. Refer to ASSEMBLY (PD-35).
5. Ring and pinion gear tooth contact pattern

Side Bearing Preload

A selection of carrier side bearing adjusting washer is
required for successful completion of this procedure.

1. Make sure all parts are clean and that the bearings are well
TM
lubricated with light oil or ‘‘DEXRON ’’ type automatic transmission
fluid.
2. Place the differential carrier, with side bearings and bearing
races installed, into the final drive housing.

SPD527

3. Put the side bearing spacer in place.

CAUTION:
Side bearing spacer is placed on either the right or left
depending upon final drive gear ratio. Be sure to replace it on
the correct side.

SPD894

4. Using Tool, install original carrier side bearing preload shims

on the carrier end, opposite the ring gear.
Tool number: KV38100600 (J25267)

SPD986

PD-24
 ADJUSTMENT R200A
Side Bearing Preload (Cont’d)
5. Install the side bearing caps in their correct locations and GI
torque the bearing cap retaining bolts.
Specification:
88 - 98 Nzm (9 - 10 kg-m, 65 - 72 ft-lb) MA
6. Turn the carrier several times to seat the bearings.

EM

LC
SPD526

7. Measure the turning torque of the carrier at the ring gear retain- EC
ing bolts with a spring gauge, J8129.
Specification:
34.3 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb) FE
of pulling force at the ring gear bolt.

CL

MT
SPD194A

8. If the carrier turning torque is not within the specification range, AT

increase or decrease the total thickness of the side bearing
adjusting washers until the turning torque is correct. If the
turning torque is less than the specified range, install washers TF
of greater thickness; if the turning torque is greater than the
specification, install thinner washers. See the SDS section for
washer dimensions and part numbers. PD
9. Record the total amount of washer thickness required for the
correct carrier side bearing preload.
FA
SPD772

10. Remove the carrier from the final drive housing, saving the RA
selected preload washers for later use during the assembly of
the final drive unit.
BR

ST

RS
SPD668
BT
Pinion Gear Height and Pinion Bearing Preload
1. Make sure all parts are clean and that the bearings are well
lubricated. HA
2. Assemble the pinion gear bearings into the pinion pre-load
shim selector Tool, J34309.
EL

IDX
SPD769

PD-25
 ADJUSTMENT R200A
Pinion Gear Height and Pinion Bearing Preload
(Cont’d)
● Front Pinion Bearing — make sure the J34309-3 front pinion
bearing seat is secured tightly against the J34309-2 gauge
anvil. Then turn the front pinion bearing pilot, J34309-5, to
secure the bearing in its proper position.
● Rear Pinion Bearing — the rear pinion bearing pilot, J34309-
15, is used to center the rear pinion bearing only. The rear
pinion bearing locking seat, J34309-4, is used to lock the bear-
ing to the assembly.

SPD197A

3. Place the pinion preload shim selector Tool, J34309-1, gauge

screw assembly with the pinion rear bearing inner cone
installed into the final drive housing.

SPD893

4. Assemble the front pinion bearing inner cone and the J34309-2
gauge anvil together with the J34309-1 gauge screw in the
final drive housing. Make sure that the pinion height gauge
plate, J34309-16, will turn a full 360 degrees, and tighten the
two sections together by hand.

SPD199A

5. Turn the assembly several times to seat the bearings.

SPD770

6. Measure the turning torque at the end of the J34309-2 gauge

anvil using torque wrench J25765A.
Turning torque specification:
1.0 - 1.3 Nzm (10 - 13 kg-cm, 8.7 - 11.3 in-lb)

SPD234A

PD-26
 ADJUSTMENT R200A
Pinion Gear Height and Pinion Bearing Preload
(Cont’d) GI
7. Place the J34309-1 ‘‘R200A’’ pinion height adapter onto the
gauge plate and tighten it by hand.
MA
CAUTION:
Make sure all machined surfaces are clean.
EM

LC
SPD208A

PINION BEARING PRELOAD WASHER SELECTION EC

8. Place the solid pinion bearing spacer, small end first, over the
J34309-2 gauge anvil and seat the small end squarely against
FE
the tip of the J34309-1 gauge screw in the tool recessed por-
tion.
CL

MT
SPD209A

AT

TF

PD

FA
SPD773

9. Select the correct thickness of pinion bearing preload adjust- RA

ing washer using a standard gauge of 3.5 mm (0.138 in) and
your J34309-101 feeler gauge. The exact measure you get
with your gauges is the thickness of the adjusting washer BR
required. Select the correct washer.
Drive pinion bearing preload adjusting washer:
Refer to SDS (PD-59). ST
10. Set your selected, correct pinion bearing preload adjusting
washer aside for use when assembling the pinion gear and
bearings into the final drive. RS
SPD210A
BT

HA

EL

IDX
SPD774

PD-27
 ADJUSTMENT R200A
Pinion Gear Height and Pinion Bearing Preload
(Cont’d)
PINION HEIGHT ADJUSTING WASHER SELECTION
11. Now, position the side bearing discs, J25269-4, and arbor
firmly into the side bearing bores.

SPD211A

12. Install the side bearing caps and tighten the cap bolts.
Specification:
88 - 98 Nzm (9 - 10 kg-m, 65 - 72 ft-lb)

SPD212A

13. Select the correct standard pinion height adjusting washer

thickness by using a standard gauge of 3.0 mm (0.118 in) and
your J34309-101 feeler gauge. Measure the gap between the
J34309-11 ‘‘R200A’’ pinion height adapter and the arbor.

SPD204A

14. Write down your exact total measurement.

SPD775

15. Correct the pinion height washer size by referring to the ‘‘pin-
ion head number’’.
There are two numbers painted on the pinion gear. The first
one refers to the pinion and ring gear as a matched set and
should be the same as the number on the ring gear. The sec-
ond number is the ‘‘pinion head height number’’, and it refers
to the ideal pinion height from standard for quietest operation.

SPD542

PD-28
 ADJUSTMENT R200A
Pinion Gear Height and Pinion Bearing Preload
(Cont’d) GI
Use the following chart to determine the correct pinion height
washer.
MA
Add or Remove from the Standard
Pinion Head Height Number Pinion Height Washer Thickness
Measurement EM
−6 Add 0.06 mm (0.0024 in)
−5 Add 0.05 mm (0.0020 in) LC
−4 Add 0.04 mm (0.0016 in)
−3 Add 0.03 mm (0.0012 in)
EC
−2 Add 0.02 mm (0.0008 in)
−1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness FE
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in) CL
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in) MT
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)
AT
16. Select the correct drive pinion height washer.
Drive pinion height adjusting washer:
Refer to SDS (PD-59). TF

PD

FA

17. Remove the J34309 pinion preload shim selector tool from the RA
final drive housing and disassemble to retrieve the pinion bear-
ings.
BR

ST

RS
SPD205A
BT

HA

EL

IDX

PD-29
 ADJUSTMENT R200A

Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gear sets which are not positioned properly in relation to
one another may be noisy, or have short life, or both. With a pat-
tern check, the most desirable contact for low noise level and long
life can be assured.

1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.

SPD357

3. Hold companion flange steady by hand and rotate the ring gear
in both directions.

SPD677

SPD007-B

PD-30
 ASSEMBLY R200A

Differential Side Shaft GI

1. Install oil seal and grease seal.
MA

EM

LC
SPD782-A

EC

FE

CL

MT
SPD654-A

2. Install extension tube retainer, rear axle bearing and rear axle AT
shaft bearing collar on differential side shaft.
TF

PD

FA
SPD655

RA
Differential Case
1. Install side gears, pinion mate gears and thrust washers into
differential case. BR

ST

RS
SPD552

2. Fit pinion mate shaft to differential case so that it meets lock

BT
pin holes.
3. Adjust backlash between side gear and pinion mate gear by
selecting side gear thrust washer. HA
Refer to SDS (PD-58).
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and EL
differential case):
Less than 0.15 mm (0.0059 in)
IDX
SPD258

PD-31
 ASSEMBLY R200A
Differential Case (Cont’d)
4. Install pinion mate shaft lock pin with a punch.
Make sure lock pin is flush with case.

SPD030

5. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see they turn properly.

SPD322

6. Install differential case assembly on ring gear.

7. Apply locking agent [Locktite (stud lock) or equivalent] to ring
gear bolts, and install them.
Tighten bolts in a criss-cross pattern, lightly tapping bolt head
with a hammer.

SPD554

8. Press-fit side bearing inner cones on differential case with Tool.

Tool number:
s A KV38100300 (J25523)
s B ST33061000 (J8107-2)

PD353

PD-32
 ASSEMBLY R200A

Final Drive Housing GI

1. Press-fit front and rear bearing outer races with Tools.
Tool number: MA
s A ST30611000 (J25742-1)
s B ST30621000 (J25742-5)
s C ST30613000 (J25742-3)
EM

LC

EC

FE

CL

MT
SPD679

2. Select drive pinion height adjusting washer and pinion bearing AT

adjusting washer. Refer to ADJUSTMENT (PD-25).
3. Install drive pinion height adjusting washer in drive pinion, and
press-fit pinion rear bearing inner cone in it, using press and TF
Tool.
Tool number:
ST30901000 (J26010-01) PD

FA
SPD377

4. Place pinion front bearing inner cone in final drive housing. RA

BR

ST

RS
SPD581

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.

BT
Install front oil seal.
Tool number:
KV38100500 (J25273) HA

EL

IDX
SPD680

PD-33
 ASSEMBLY R200A
Final Drive Housing (Cont’d)
6. Place drive pinion bearing spacer, drive pinion bearing adjust-
ing washer and drive pinion in final drive housing.

SPD658

7. Insert companion flange into drive pinion by tapping the com-

panion flange with a soft hammer.

SPD681

8. Tighten pinion nut to the specified torque.

The threaded portion of drive pinion and pinion nut should be
free from oil or grease.
Tool number: ST38060002 (J34311)

PD466

9. Turn drive pinion in both directions several revolutions, and

measure pinion bearing preload.
Tool number: ST3127S000 (J25765-A)
Pinion bearing preload:
1.1 - 1.4 Nzm
(11 - 14 kg-cm, 9.5 - 12.2 in-lb)
When pinion bearing preload is outside the specifications,
replace pinion bearing adjusting washer and spacer with a
different thickness.

SPD664

10. Select side bearing adjusting washer.

Refer to ADJUSTMENT (PD-24).
11. Install differential case assembly with side bearing outer races
into final drive housing.

SPD527

PD-34
 ASSEMBLY R200A
Final Drive Housing (Cont’d)
12. Insert left and right side bearing adjusting washers in place GI
between side bearings and final drive housing.

MA

EM

LC
SPD558

13. Drive in side bearing spacer with Tool. EC

Tool number: KV38100600 (J25267)
FE

CL

MT
SPD559

14. Align mark on bearing cap with that on final drive housing and AT
install bearing cap on final drive housing.
TF

PD

FA
SPD526

15. Apply multi-purpose grease to cavity at sealing lips of oil seal. RA

Install side oil seal.
Tool number: KV38100200 (J26233)
BR

ST

RS
SPD560

16. Measure ring gear to drive pinion backlash with a dial indica-
BT
tor.
Ring gear-to-drive pinion backlash:
0.10 - 0.15 mm (0.0039 - 0.0059 in) HA
● If backlash is too small, decrease thickness of right shim and
increase thickness of left shim by the same amount.
If backlash is too great, reverse the above procedure. EL
Never change the total amount of shims as it will change the
bearing preload.
IDX
SPD513

PD-35
 ASSEMBLY R200A
Final Drive Housing (Cont’d)
17. Check total preload with Tool.
When checking preload, turn drive pinion in both directions
several times to set bearing rollers.
Tool number: ST3127S000 (J25765-A)
Total preload:
1.4 - 1.7 Nzm
(14 - 17 kg-cm, 12 - 15 in-lb)

SPD664

● If preload is too great, remove the same amount of shim from

each side.
● If preload is too small, add the same amount of shim to each
side.
Never add or remove a different number of shims for each side
as it will change ring gear to drive pinion backlash.
18. Recheck ring gear to drive pinion backlash because increase
or decrease in thickness of shims will cause change of ring
gear-to-pinion backlash.

SPD561

19. Check runout of ring gear with a dial indicator.

Runout limit:
0.05 mm (0.0020 in)
● If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the ring
gear and the differential case.
● If the backlash varies greatly when the runout of the ring gear
is within a specified range, the hypoid gear set or differential
case should be replaced.
20. Check tooth contact. Refer to ADJUSTMENT (PD-30).
21. Install rear cover and gasket.
SPD524

22. Install differential side shaft assembly.

SPD682

PD-36
REAR FINAL DRIVE H233B

GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

SPD427A

PD-37
 DISASSEMBLY H233B

Pre-inspection
Before disassembling final drive, perform the following inspection.
● Total preload
a. Turn drive pinion in both directions several times to seat bear-
ing rollers correctly.
b. Check total preload with Tool.
Total preload (With front oil seal):
Drive pinion bearing
New: 1.5 - 1.7 Nzm (15 - 17 kg-cm, 13 - 15 in-lb)
Old: 1.7 - 2.5 Nzm (17 - 25 kg-cm, 15 - 22 in-lb)
SPD149 Tool number: ST3127S000 (J25765-A)
● Ring gear-to-drive pinion backlash
Check backlash of ring gear with a dial indicator at several
points.
Ring gear-to-drive pinion backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in)

SPD246

● Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit:
0.08 mm (0.0031 in)

SPD247

● Tooth contact
Check tooth contact, referring to ‘‘ADJUSTMENT’’, PD-52.
● Side gear-to-pinion mate gear backlash
Measure clearance between side gear thrust washer and dif-
ferential case with a feeler gauge.
Clearance between side gear thrust washer and
differential case:
0.1 - 0.2 mm (0.004 - 0.008)

SPD004

Differential Carrier
1. Mount final drive assembly on Tool.
Tool numbers:
s A ST0501S000 ( — )
s B ST06340000 (J24310, J34310)

SPD139

PD-38
 DISASSEMBLY H233B
Differential Carrier (Cont’d)
2. Put match marks on one side of side bearing cap with paint or GI
punch to ensure that it is replaced in proper position during
reassembly.
Bearing caps are line-bored during manufacture and should MA
be put back in their original places.
EM

LC
SPD249

3. Remove side lock fingers and side bearing caps. EC

FE

CL

MT
SPD250

4. Remove side bearing adjuster with Tool. AT

Tool number: ST32580000 (J34312)
TF

PD

FA
SPD684

5. Remove differential case assembly with a pry bar. RA

BR

ST

RS
SPD685
BT
Keep the side bearing outer races together with their respec-
tive inner cones — do not mix them up.
HA

EL

IDX
SPD011

PD-39
 DISASSEMBLY H233B
Differential Carrier (Cont’d)
6. Remove drive pinion nut with Tool.
Tool number: KV38104700 (J34311)
7. Remove companion flange with puller.
8. Remove ABS sensor.

SPD213A

9. Take out drive pinion together with pinion rear bearing inner
cone, drive pinion bearing spacer and pinion bearing adjusting
shim.

SPD687

10. Remove front oil seal and pinion front bearing inner cone.
11. Remove pinion bearing outer races with a brass drift.

SPD563

12. Remove pinion rear bearing inner cone and drive pinion adjust-
ing washer.
Tool number: ST30031000 (J22912-01)

SPD018

Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove.
Tool numbers:
sA ST33051001 (J22888-20)
sB ST33061000 (J8107-2)

SPD207A

PD-40
 DISASSEMBLY H233B
Differential Case (Cont’d)
Be careful not to confuse the left and right hand parts. GI

MA

EM

LC
SPD022

2. Spread out lock straps and loosen ring gear bolts in a criss- EC
cross fashion.
FE

CL

MT
SPD689

3. Tap ring gear off differential case with a soft hammer. AT

Tap evenly all around to keep ring gear from binding.
TF

PD

FA
SPD024

4. Separate differential case LH and RH. RA

Put match marks on both differential case LH and RH sides
prior to separating them.
BR

ST

RS
SPD716
BT

HA

EL

IDX

PD-41
 INSPECTION H233B

Ring Gear and Drive Pinion

Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive pinion
as a set (hypoid gear set).

Differential Case Assembly

Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft, and thrust washers.

SPD717

Bearing
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner cone as a set.

SPD715

PD-42
LIMITED SLIP DIFFERENTIAL H233B

GI

MA

EM

LC

EC

FE

CL

SPD423A MT

CAUTION:
AT
Do not run engine when only one wheel (rear) is off the
ground.
TF
Preparation for Disassembly
CHECKING DIFFERENTIAL TORQUE PD
Measure differential torque with Tools.
If it is not within the specifications, inspect components of limited
slip differential.
FA
SPD415 Differential torque:
201 - 240 Nzm
(20.5 - 24.5 kg-m, 148 - 177 ft-lb) RA
Tool numbers:
sA KV38105210 ( — )
BR
sB KV38105220 ( — )

ST

RS

BT
Disassembly
1. Remove side bearing inner cone with Tool.
2. Loosen ring gear bolts in a criss-cross fashion. HA
3. Tap ring gear off gear case with a soft hammer.
Tap evenly all around to keep ring gear from binding.
EL

IDX
SPD424A

PD-43
LIMITED SLIP DIFFERENTIAL H233B
Disassembly (Cont’d)
4. Remove couple bolts on differential cases A and B with a
press.
Tool number: ST33081000 ( — )
5. Separate differential cases A and B.
Draw out component parts (discs and plates, etc.).
Put marks on differential cases so that they can be reinstalled
in their original positions.

SPD420A

Inspection
CONTACT SURFACES
1. Clean the disassembled parts in suitable solvent and blow dry
with compressed air.
2. If the following surfaces are found with burrs or scratches,
smooth with oil stone.
s1 Differential case B
s2 Differential case A
s3 Side gear
s4 Pinion mate gear
s5 Pinion mate shaft
s6 Thrust block
s7 Friction plate guide

SPD291

DISC AND PLATE

1. Clean the discs and plates in suitable solvent and blow dry with
compressed air.
2. Inspect discs and plates for wear, nicks and burrs.

3. Check friction discs or plates for warpage.

Allowable warpage:
0.08 mm (0.0031 in)
If it exceeds limits, replace with a new disc or plate to eliminate
possibility of clutch slippage or sticking.

SPD279

PD-44
LIMITED SLIP DIFFERENTIAL H233B
Inspection (Cont’d)
4. Measure frictional surfaces and projected portions of friction GI
discs, plates, spring disc and plate.
If any part has worn beyond the wear limit, replace it with a
new one that is the same thickness as the projected portion. MA
Wear limit:
0.1 mm (0.004 in) or less
EM

LC

EC

FE

CL

MT
SPD421A

Adjustment AT

FRICTION DISC AND FRICTION PLATE END PLAY

End play of friction disc and friction plate can be calculated by using TF
the following equation and should be adjusted within the following
range.
Adjustment can be made by selecting friction disc having two dif- PD
ferent thicknesses.
End play E:
0.05 - 0.15 mm (0.0020 - 0.0059 in) FA
SPD428A
E = A − (B + C)
A: Length of differential case contact surface to differen-
tial case inner bottom. RA
B: Total thickness of friction discs, friction plates, spring
disc and spring plate in differential case on one side.
C: Length of differential case contact surface to back side BR
of side gear.
ST

RS

1. Measure values of ‘‘A’’.

BT
Standard length A:
49.50 - 49.55 mm (1.9488 - 1.9508 in)
HA

EL

IDX
SPD417

PD-45
LIMITED SLIP DIFFERENTIAL H233B
Adjustment (Cont’d)
2. Measure thickness of each disc and plate.
Total thickness ‘‘B’’:
19.24 - 20.26 mm (0.7575 - 0.7976 in)
No. of discs and plates (One side):
Friction disc 5
Friction plate 6
Spring disc 1
Spring plate 1

SPD420

3. Measure values of ‘‘C’’.

a. Attach a dial indicator to the base plate.
b. Place differential case B on the base plate, and install a mas-
ter gauge on case B.
Then adjust the dial indicator scale to zero with its tip on the
master gauge.

SPD418

c. Install pinion mate gears, side gears and pinion mate shaft in
differential case B.
d. Set dial indicator’s tip on the side gear, and read the indication.
Example:
E = A − D = A − (B + C) = 0.05 to 0.15 mm
A = 49.52 mm
B = 19.45 mm
C = 29.7 mm
D=B+C E=A−D
B ... 19.45 A ... 49.52
+C ... 29.7 −D ... 49.15
SPD419
49.15 0.37
From the above equation, end play of 0.37 mm exceeds the speci-
fied range of 0.05 to 0.15 mm.
Select suitable discs and plates to adjust correctly.

Assembly
Prior to assembling discs and plates, properly lubricate them by
dipping them in limited slip differential oil.
1. Alternately position specified number of friction plates and fric-
tion discs on rear of side gear.
Always position a friction plate first on rear of side gear.

SPD421

PD-46
LIMITED SLIP DIFFERENTIAL H233B
Assembly (Cont’d)
2. Install spring disc. GI
Align the twelve angular holes in spring disc with the hexago-
nal area of the side gear.
MA

EM

LC
SPD422

3. Install spring plate. EC

FE

CL

MT
SPD423

4. Install friction plate guides. AT

Correctly align the raised portions of friction plates, and apply
grease to inner surfaces of friction plate guides to prevent
them from falling. TF

PD

FA
SPD424

5. Install differential case B over side gear, discs, plates and fric- RA
tion plate guide assembly.
● Install differential case B while supporting friction plate
BR
guides with your middle finger by inserting through oil
hole in differential case.
● Be careful not to detach spring disc from the hexagonal
part of the side gear.
ST

RS
SPD425

6. Install pinion mate gears and pinion shaft to differential

BT
case B.
HA

EL

IDX
SPD426

PD-47
LIMITED SLIP DIFFERENTIAL H233B
Assembly (Cont’d)
7. Install thrust block.

SPD427

8. Install side gear to pinion mate gears.

9. Install each disc and plate.
Use same procedures as outlined in steps 1. through 4.

SPD429

10. Install differential case A.

Position differential cases A and B by correctly aligning marks
stamped on cases.

SPD430

11. Tighten differential case bolts.

12. Place ring gear on differential case and install new lock straps
and bolts.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.
Then bend up lock straps to lock the bolts in place.
13. Install side bearing inner cone.
14. Check differential torque.

SPD288

PD-48
 ADJUSTMENT H233B

For quiet and reliable final drive operation, the following five adjust- GI
ments must be made correctly:
1. Side bearing preload
2. Pinion gear height MA
3. Side bearing preload
4. Ring gear-to-pinion backlash. Refer to Differential Carrier,
‘‘ASSEMBLY’’, (PD-54). EM
5. Ring and pinion gear tooth contact pattern

LC

Pinion Gear Height EC

1. Make sure all parts are clean and that the bearings are well
lubricated. FE
2. Assemble the pinion gear bearings into the pinion pre-load
shim selector tool, J34309.
CL

MT
SPD196A

● Rear Pinion Bearing — the rear pinion bearing pilot,

AT
J34309-8, is used to center the rear pinion bearing only. The
rear pinion bearing locking seat, J34309-4, is used to lock the
bearing to the assembly. TF
● Front Pinion Bearing — make sure the J34309-3, front pin-
ion bearing seat is secured tightly against the J34309-2 gauge PD
anvil. Then turn the front pinion bearing pilot, J34309-5, to
secure the bearing in its proper position.
FA
SPD197A

3. Place the pinion preload shim selector tool gauge screw RA

assembly, J34309-1, with the pinion rear bearing inner cone
installed, into the final drive housing.
BR

ST

RS
SPD216A

4. Install the J34309-2 gauge anvil with the front pinion bearing
BT
into the final drive housing and assemble it to the J34309-1
gauge screw. Make sure that the J34309-16 gauge plate will
turn a full 360 degrees, and tighten the two sections by hand HA
to set bearing pre-load.
5. Turn the assembly several times to seat the bearings.
EL

IDX
SPD217A

PD-49
 ADJUSTMENT H233B
Pinion Gear Height (Cont’d)
6. Measure the turning torque at the end of the J34309-2 gauge
anvil using torque wrench J25765A.
Turning torque specification:
0.4 - 0.9 Nzm (4 - 9 kg-cm, 3.5 - 7.8 in-lb)

SPD234A

7. Place the J34309-12 ‘‘H233B’’ pinion height adapter onto the

gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

SPD208A

PINION HEIGHT ADJUSTING WASHER SELECTION

8. Position the J25269-18 side bearing discs and the arbor into
the side bearing bores.

SPD286A

9. Install the bearing caps and torque the bolts.

Specification:
93 - 103 Nzm (9.5 - 10.5 kg-m, 69 - 76 ft-lb)

SPD237A

10. Select the correct standard pinion height adjusting washer

thickness using a standard gauge of 2.5, 3.0, or 3.5 mm
(0.098, 0.118, or 0.138 in) and your J34309-101 feeler gauge.
Measure the distance between the J34309-12 ‘‘H233B’’ pinion
height adapter and the arbor.

SPD204A

PD-50
 ADJUSTMENT H233B
Pinion Gear Height (Cont’d)
11. Write down your exact total measurement. GI

MA

EM

LC
SPD779

12. Correct the pinion height washer size by referring to the ‘‘pin- EC
ion head height number’’.
There are two numbers painted on the pinion gear. The first
one refers to the pinion and ring gear as a matched set and FE
should be the same as the number on the ring gear. The sec-
ond number is the ‘‘pinion head height number’’, and it refers
to the ideal pinion height from standard for the quietest opera- CL
tion. Use the following chart to determine the correct pinion
height washer.
MT
SPD542

AT
Add or Remove from the Selected
Pinion Head Height Number Standard Pinion Height Washer
Thickness Measurement TF
−6 Add 0.06 mm (0.0024 in)
−5 Add 0.05 mm (0.0020 in)
−4 Add 0.04 mm (0.0016 in) PD
−3 Add 0.03 mm (0.0012 in)
−2 Add 0.02 mm (0.0008 in) FA
−1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
+1 Subtract 0.01 mm (0.0004 in) RA
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
BR
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in) ST
13. Select the correct pinion height washer.
Drive pinion height adjustment:
Refer to SDS (PD-60).
RS

14. Remove the J34309 pinion preload shim selector tool from the
BT
final drive housing and disassemble to retrieve the pinion bear-
ings.
HA

EL

IDX
SPD220A

PD-51
 ADJUSTMENT H233B

Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gear sets which are not positioned properly may be noisy,
or have short life or both. With a pattern check, the most desirable
contact for low noise level and long life can be assured.

1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.

SPD005

3. Hold companion flange steady and rotate the ring gear in both
directions.

SPD695

SPD007-B

PD-52
 ASSEMBLY H233B

Differential Case GI
1. Measure clearance between side gear thrust washer and dif-
ferential case. MA
Clearance between side gear thrust washer
and differential case (A − B):
Less than 0.15 mm (0.0059 in) EM
The clearance can be adjusted with side gear thrust washer.
Refer to SDS, PD-59.
2. Apply gear oil to gear tooth surfaces and thrust surfaces and
LC
check to see they turn properly.

EC

FE

CL

MT
SPD656

3. Install differential case LH and RH. AT

4. Install differential case on ring gear.
TF

PD

FA
SPD643

5. Place differential case on ring gear. RA

6. Apply locking agent [Locktite (stud lock) or equivalent] to ring
gear bolts, and install them.
BR
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.
ST

RS
SPD746

7. Press-fit side bearing inner cones on differential case with Tool.

BT
Tool numbers:
s A ST33190000 (J25523)
HA
s B ST33081000 ( — )

EL

IDX
PD353

PD-53
 ASSEMBLY H233B

Differential Carrier
1. Press-fit front and rear bearing outer races with Tools.
Tool numbers:
s A ST30611000 (J25742-1)
s B ST30621000 (J25742-5)
s C ST30613000 (J25742-3)

SPD580

2. Select drive pinion height adjusting washer. Refer to

‘‘ADJUSTMENT’’, PD-49.
3. Install drive pinion adjusting washer in drive pinion, and press-
fit pinion rear bearing inner cone in it, with press and Tool.
Tool number: ST30901000 (J26010-01)

SPD377

4. Place pinion front bearing inner cone in gear carrier.

SPD581

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.

Install front oil seal.
Tool numbers:
sA ST30720000 (J25405)
sB KV38102510 ( — )

SPD291A

PD-54
 ASSEMBLY H233B
Differential Carrier (Cont’d)
6. Install drive pinion bearing spacer, pinion bearing adjusting GI
shim and drive pinion in gear carrier.

MA

EM

LC
SPD935-A

7. Insert companion flange into drive pinion by tapping the com- EC

panion flange with a soft hammer.
FE

CL

MT
SPD697

8. Tighten pinion nut to the specified torque. AT

The threaded portion of drive pinion and pinion nut should be
free from oil or grease.
Tool number: KV38104700 (J34311) TF

PD

FA
SPD040

9. Turn drive pinion in both directions several times, and measure RA

pinion bearing preload.
Tool number: ST3127S000 (J25765-A)
Pinion bearing preload (With front oil seal): BR
1.4 - 1.7 Nzm (14 - 17 kg-cm, 12 - 15 in-lb)
Pinion bearing preload (Without front oil seal):
1.2 - 1.5 Nzm (12 - 15 kg-cm, 10 - 13 in-lb) ST
If preload is out of specification, adjust the thickness of spacer and
shim combination by replacing shim and spacer with thinner one.
● Start from the combination of thickest spacer and shim. RS
● Combine each spacer and shim thickness one by one until the
SPD149
correct specification is achieved.
10. Install differential case assembly with side bearing outer races
BT
into gear carrier.
11. Position side bearing adjusters on gear carrier with threads
properly engaged; screw in adjusters lightly at this stage of HA
assembly.
Tool number: ST32580000 (J34312)
EL

IDX
SPD684

PD-55
 ASSEMBLY H233B
Differential Carrier (Cont’d)
12. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.
● Do not tighten at this point to allow further tightening of side
bearing adjusters.

SPD265

13. Tighten both right and left side bearing adjusters alternately
and measure ring gear backlash and total preload at the same
time. Adjust right and left side bearing adjusters by tightening
them alternately so that proper ring gear backlash and total
preload can be obtained.
Ring gear-to-drive pinion backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in)

SPD246

● When checking preload, turn drive pinion in both direc-

tions several times to set bearing rollers.
Tool number: ST3127S000 (J25765-A)
Total preload (With front oil seal):
Drive pinion bearing
New: 1.5 - 1.7 Nzm (15 - 17 kg-cm, 13 - 15 in-lb)
Old: 1.7 - 2.5 Nzm (17 - 25 kg-cm, 15 - 22 in-lb)

SPD149

14. Tighten side bearing cap bolts.

15. Install side lock finger in place to prevent rotation during opera-
tion.

SPD698

16. Check runout of ring gear with a dial indicator.

Runout limit: 0.08 mm (0.0031 in)
● If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the ring
gear and the differential case.
● If the backlash varies greatly when the runout of the ring gear
is within a specified range, the hypoid gear set or differential
case should be replaced.
17. Check tooth contact. Refer to ‘‘ADJUSTMENT’’, PD-52.

SPD247

PD-56
 SERVICE DATA AND SPECIFICATIONS (SDS)

Propeller Shaft GI
GENERAL SPECIFICATIONS
Location Front Rear
MA
Propeller shaft model 2F1310 3S1310
Number of joints 2 3 EM
Coupling method with transmission Flange type Sleeve type
Type of journal bearings Solid type (disassembly type)
LC
Shaft length
1st 542 (21.3) 398 (15.7)
(Spider to spider)
mm (in) 2nd — 840.3 (33.1) EC
Shaft diameter 1st 50.8 (2.0) 76.2 (3.0)
mm (in) 2nd — 76.2 (3.0)
FE
INSPECTION AND ADJUSTMENT
Service data Unit: mm (in)
CL
Propeller shaft runout limit 0.6 (0.024)
Journal axial play 0.02 (0.0008) or less MT

Snap ring Unit: mm (in)

AT
Thickness Color Part number
1.99 (0.0783) White 37146-C9400
2.02 (0.0795) Yellow 37147-C9400 TF
2.05 (0.0807) Red 37148-C9400
2.08 (0.0819) Green 37149-C9400 PD
2.11 (0.0831) Blue 37150-C9400
2.14 (0.0843) Light brown 37151-C9400
FA
2.17 (0.0854) Black 37152-C9400
2.20 (0.0866) No paint 37153-C9400
RA

BR

ST

RS

BT

HA

EL

IDX

PD-57
 SERVICE DATA AND SPECIFICATIONS (SDS)

Final Drive
GENERAL SPECIFICATIONS
Grade XE SE
Front final drive R200A R200A
2-pinion 2-pinion
4.375
Gear ratio 4.625
4.625 *1
Oil capacity (Approx.) 1.5 1.5
l (US pt, Imp pt) (3-1/8, 2-5/8) (3-1/8, 2-5/8)
Rear final drive H233B H233B
Standard Optional Standard Optional
4-pinion LSD 4-pinion LSD
4.375
Gear ratio 4.625
4.625*1
Number of teeth 35/8
37/8
(Ring gear/drive pinion) 37/8 *1
Oil capacity (Approx.) 2.8 2.8
l (US pt, Imp pt) (5-7/8, 4-7/8) (5-7/8, 4-7/8)

*1 Optional tire (P265/70R15) equipped models.

INSPECTION AND ADJUSTMENT (R200A)
Ring gear runout Side bearing adjustment
Ring gear runout limit mm (in) 0.05 (0.0020) Differential carrier assembly turning 34.3 - 39.2
resistance N (kg, lb) (3.5 - 4.0, 7.7 - 8.8)

Side gear adjustment Available side bearing adjusting washers

Thickness mm (in) Part number
Side gear backlash
(Clearance between side gear and Less than 0.15 (0.0059) 2.00 (0.0787) 38453-N3100
differential case) mm (in) 2.05 (0.0807) 38453-N3101
2.10 (0.0827) 38453-N3102
Available side gear thrust washers
2.15 (0.0846) 38453-N3103
Thickness mm (in) Part number 2.20 (0.0866) 38453-N3104
2.25 (0.0886) 38453-N3105
0.75 (0.0295) 38424-N3110 2.30 (0.0906) 38453-N3106
0.78 (0.0307) 38424-N3111 2.35 (0.0925) 38453-N3107
0.81 (0.0319) 38424-N3112 2.40 (0.0945) 38453-N3108
0.84 (0.0331) 38424-N3113 2.45 (0.0965) 38453-N3109
0.87 (0.0343) 38424-N3114 2.50 (0.0984) 38453-N3110
0.90 (0.0354) 38424-N3115 2.55 (0.1004) 38453-N3111
0.93 (0.0366) 38424-N3116 2.60 (0.1024) 38453-N3112

PD-58
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont’d)
INSPECTION AND ADJUSTMENT (R200A) INSPECTION AND ADJUSTMENT (H233B) GI
(CONT’D)
Ring gear runout
Total preload adjustment Ring gear runout limit mm (in) 0.08 (0.0031) MA
Total preload 1.4 - 1.7
Nzm (kg-cm, in-lb) (14 - 17, 12 - 15) Side gear adjustment (without LSD)
0.10 - 0.15 EM
Ring gear backlash mm (in) Side gear backlash
(0.0039 - 0.0059)
(Clearance between side gear to 0.1 - 0.2 (0.004 - 0.008)
differential case) mm (in)
Drive pinion height adjustment Available side gear thrust washers
LC
Available pinion height adjusting washers
Thickness mm (in) Part number
Thickness mm (in) Part number
1.75 (0.0689) 38424-T5000 EC
3.09 (0.1217) 38154-P6017 1.80 (0.0709) 38424-T5001
3.12 (0.1228) 38154-P6018 1.85 (0.0728) 38424-T5002
3.15 (0.1240) 38154-P6019
3.18 (0.1252) 38154-P6020 FE
3.21 (0.1264) 38154-P6021 — Additional service for LSD model —
3.24 (0.1276) 38154-P6022
3.27 (0.1287) 38154-P6023 Differential torque adjustment
3.30 (0.1299) 38154-P6024
CL
3.33 (0.1311) 38154-P6025 Differential torque 201 - 240
3.36 (0.1323) 38154-P6026 Nzm (kg-m, ft-lb) (20.5 - 24.5, 148 - 177)
3.39 (0.1335) 38154-P6027
3.42 (0.1346) 38154-P6028
Number of discs and plates MT
3.45 (0.1358) 38154-P6029 Friction disc 10
3.48 (0.1370) 38154-P6030 Friction plate 12
3.51 (0.1382) 38154-P6031 Spring disc 2 AT
3.54 (0.1394) 38154-P6032 Spring plate 2
3.57 (0.1406) 38154-P6033
3.60 (0.1417) 38154-P6034 Wear limit of plate and disc
0.1 (0.004)
3.63 (0.1429) 38154-P6035 mm (in) TF
3.66 (0.1441) 38154-P6036
Allowable warpage of friction disc
0.08 (0.0031)
and plate mm (in)
Drive pinion preload adjustment Total thickness mm (in) 19.24 - 20.26 (0.7575 - 0.7976) PD
Drive pinion bearing preload adjusting Adjusting washer and Available discs and plates
method spacer
Part name Thickness mm (in) Part number
Drive pinion preload
FA
Nzm (kg-cm, in-lb) 1.48 - 1.52 38433-C6000
1.1 - 1.4 (0.0583 - 0.0598) (Standard type)
With front oil seal Friction disc
(11 - 14, 9.5 - 12.2)
1.58 - 1.62 38433-C6001 RA
Available drive pinion bearing preload adjusting washers (0.0622 - 0.0638) (Adjusting type)

Thickness mm (in) Part number 1.48 - 1.52

Friction plate 38432-C6000
3.81 (0.1500) 38125-61001
(0.0583 - 0.0598) BR
3.83 (0.1508) 38126-61001 1.48 - 1.52
Spring disc 38436-C6000
3.85 (0.1516) 38127-61001 (0.0583 - 0.0598)
3.87 (0.1524) 38128-61001
1.48 - 1.52
ST
3.89 (0.1531) 38129-61001 Spring plate 38435-C6010
3.91 (0.1539) 38130-61001 (0.0583 - 0.0598)
3.93 (0.1547) 38131-61001
3.95 (0.1555) 38132-61001 RS
3.97 (0.1563) 38133-61001
3.99 (0.1571) 38134-61001
4.01 (0.1579) 38135-61001
4.03 (0.1587) 38136-61001 BT
4.05 (0.1594) 38137-61001
4.07 (0.1602) 38138-61001
4.09 (0.1610) 38139-61001
HA
Available drive pinion bearing preload adjusting spacers
Length mm (in) Part number
54.50 (2.1457) 38165-B4000 EL
54.80 (2.1575) 38165-B4001
55.10 (2.1693) 38165-B4002
55.40 (2.1811) 38165-B4003
55.70 (2.1929) 38165-B4004 IDX
56.00 (2.2047) 38165-61001

PD-59
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont’d)
INSPECTION AND ADJUSTMENT (H233B) Drive pinion preload adjustment
(CONT’D) Drive pinion bearing preload
Adjusting shim and spacer
adjusting method
Drive pinion height adjustment
Available pinion height adjusting washers Drive pinion preload
Nzm (kg-cm, in-lb)
Thickness mm (in) Part number
1.4 - 1.7
2.58 (0.1016) 38151-01J00 With front oil seal
(14 - 17, 12 - 15)
2.61 (0.1028) 38151-01J01
2.64 (0.1039) 38151-01J02 1.2 - 1.5
Without front oil seal
2.67 (0.1051) 38151-01J03 (12 - 15, 10 - 13)
2.70 (0.1063) 38151-01J04 Available drive pinion preload adjusting shims
2.73 (0.1075) 38151-01J05
2.76 (0.1087) 38151-01J06 Thickness mm (in) Part number
2.79 (0.1098) 38151-01J07
2.31 (0.0909) 38125-82100
2.82 (0.1110) 38151-01J08
2.33 (0.0917) 38126-82100
2.85 (0.1122) 38151-01J09
2.35 (0.0925) 38127-82100
2.88 (0.1134) 38151-01J10
2.37 (0.0933) 38128-82100
2.91 (0.1146) 38151-01J11
2.39 (0.0941) 38129-82100
2.94 (0.1157) 38151-01J12
2.41 (0.0949) 38130-82100
2.97 (0.1169) 38151-01J13
2.43 (0.0957) 38131-82100
3.00 (0.1181) 38151-01J14
2.45 (0.0965) 38132-82100
3.03 (0.1193) 38151-01J15
2.47 (0.0972) 38133-82100
3.06 (0.1205) 38151-01J16
2.49 (0.0980) 38134-82100
3.09 (0.1217) 38151-01J17
2.51 (0.0988) 38135-82100
3.12 (0.1228) 38151-01J18
2.53 (0.0996) 38136-82100
3.15 (0.1240) 38151-01J19
2.55 (0.1004) 38137-82100
3.18 (0.1252) 38151-01J60
2.57 (0.1012) 38138-82100
3.21 (0.1264) 38151-01J61
2.59 (0.1020) 38139-82100
3.24 (0.1276) 38151-01J62
3.27 (0.1287) 38151-01J63 Available drive pinion preload adjusting spacers
3.30 (0.1299) 38151-01J64
3.33 (0.1311) 38151-01J65 Length mm (in) Part number
3.36 (0.1323) 38151-01J66 4.50 (0.1772) 38165-76000
3.39 (0.1335) 38151-01J67 4.75 (0.1870) 38166-76000
3.42 (0.1346) 38151-01J68 5.00 (0.1969) 38167-76000
3.45 (0.1358) 38151-01J69 5.25 (0.2067) 38166-01J00
3.48 (0.1370) 38151-01J70 5.50 (0.2165) 38166-01J10
3.51 (0.1382) 38151-01J71
3.54 (0.1394) 38151-01J72
3.57 (0.1406) 38151-01J73
Total preload adjustment
3.60 (0.1417) 38151-01J74 1.5 - 1.7
3.63 (0.1429) 38151-01J75 Total preload New
Drive pinion (15 - 17, 13 - 15)
3.66 (0.1441) 38151-01J76 Nzm (kg-cm, in-lb)
bearing 1.7 - 2.5
With front oil seal Old
(17 - 25, 15 - 22)
0.13 - 0.18
Ring gear backlash mm (in)
(0.0051 - 0.0071)
Side bearing adjusting method Side adjuster

PD-60