Propeller Shaft & Differential Carrier

PROPELLER SHAFT &
DIFFERENTIAL CARRIER GI
SECTION PD MA
EM
LC
EC
CONTENTS FE
PROPELLER SHAFT ......................................................3 DIFFERENTIAL CASE ..............................................23

CL
Preparation ..................................................................3 DIFFERENTIAL SIDE SHAFT ...................................23
SPECIAL SERVICE TOOLS ........................................3 Inspection...................................................................24 MT
Noise, Vibration and Harshness (NVH) RING GEAR AND DRIVE PINION .............................24
Troubleshooting ...........................................................4 DIFFERENTIAL CASE ASSEMBLY ...........................25
NVH TROUBLESHOOTING CHART ............................4 BEARING ................................................................25 AT
Components.................................................................5 Adjustment .................................................................25
FRONT PROPELLER SHAFT .....................................5 SIDE BEARING PRELOAD .......................................25
REAR PROPELLER SHAFT .......................................6 PINION GEAR HEIGHT AND PINION BEARING TF
On-vehicle Service.......................................................8 PRELOAD ...............................................................27
PROPELLER SHAFT VIBRATION ...............................8 TOOTH CONTACT ...................................................31
APPEARANCE CHECKING ........................................8 Assembly ...................................................................32
Removal and Installation .............................................9 DIFFERENTIAL SIDE SHAFT ...................................32
DIFFERENTIAL CASE ..............................................32
Inspection.....................................................................9
Disassembly.................................................................9
FINAL DRIVE HOUSING ..........................................34 AX
Service Data and Specifications (SDS).....................38
CENTER BEARING ....................................................9
R200A.....................................................................38
JOURNAL ...............................................................10 SU
Assembly ...................................................................11
CENTER BEARING ..................................................11 C200
JOURNAL ...............................................................11 BR
REAR FINAL DRIVE .....................................................40
Service Data and Specifications (SDS).....................13
Preparation ................................................................40
GENERAL SPECIFICATIONS ...................................13
SPECIAL SERVICE TOOLS ......................................40
SERVICE DATA .......................................................13
Noise, Vibration and Harshness (NVH)
ST
Troubleshooting .........................................................42
R200A On-vehicle Service.....................................................43 RS
FRONT FINAL DRIVE ...................................................14 FRONT OIL SEAL REPLACEMENT...........................43
Preparation ................................................................14 REAR COVER GASKET REPLACEMENT..................43
SPECIAL SERVICE TOOLS ......................................14 Components...............................................................44 BT
Noise, Vibration and Harshness (NVH) Removal and Installation ...........................................45
Troubleshooting .........................................................16 REMOVAL ...............................................................45
On-vehicle Service.....................................................16 INSTALLATION........................................................45 HA
FRONT OIL SEAL REPLACEMENT...........................16
Disassembly...............................................................45
REAR COVER GASKET REPLACEMENT..................17 PRE-INSPECTION ...................................................45
Components...............................................................18 DIFFERENTIAL CARRIER ........................................46 SC
DIFFERENTIAL CASE ..............................................48
Removal and Installation ...........................................19
Inspection...................................................................49
REMOVAL ...............................................................19 EL
RING GEAR AND DRIVE PINION .............................49
INSTALLATION........................................................19
DIFFERENTIAL CASE ASSEMBLY ...........................49
Disassembly...............................................................20
BEARING ................................................................49
PRE-INSPECTION ...................................................20
Adjustment .................................................................49
IDX
FINAL DRIVE HOUSING ..........................................20
CONTENTS (Cont’d)
SIDE BEARING PRELOAD .......................................50 Disassembly...............................................................69
PINION GEAR HEIGHT AND PINION BEARING PRE-INSPECTION ...................................................69
PRELOAD ...............................................................51 DIFFERENTIAL CARRIER ........................................70
TOOTH CONTACT ...................................................56 DIFFERENTIAL CASE ..............................................72
Assembly ...................................................................57 Inspection...................................................................73
DIFFERENTIAL CASE ..............................................57 RING GEAR AND DRIVE PINION .............................73
DIFFERENTIAL CARRIER ........................................58 DIFFERENTIAL CASE ASSEMBLY ...........................73
Service Data and Specifications (SDS).....................62 BEARING ................................................................73
C200 .......................................................................62 Limited Slip Differential..............................................74
PREPARATION FOR DISASSEMBLY ........................74
H233B DISASSEMBLY ........................................................74
INSPECTION ...........................................................75
REAR FINAL DRIVE .....................................................64 ADJUSTMENT .........................................................76
Preparation ................................................................64 ASSEMBLY .............................................................78
SPECIAL SERVICE TOOLS ......................................64 Adjustment .................................................................79
Noise, Vibration and Harshness (NVH) PINION GEAR HEIGHT ............................................80
Troubleshooting .........................................................66 TOOTH CONTACT ...................................................83
On-vehicle Service.....................................................67 Assembly ...................................................................84
FRONT OIL SEAL REPLACEMENT...........................67 DIFFERENTIAL CASE ..............................................84
Components...............................................................68 DIFFERENTIAL CARRIER ........................................85
Removal and Installation ...........................................69 Service Data and Specifications (SDS).....................88
REMOVAL ...............................................................69 H233B.....................................................................88
INSTALLATION........................................................69
PD-2
PROPELLER SHAFT
Preparation
Preparation
SPECIAL SERVICE TOOLS
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
NEPD0001
GI
Tool number
(Kent-Moore No.) Description MA
Tool name
KV38108300 Removing and installing propeller shaft lock nut,

(J-44195) and drive pinion lock nut
EM
Companion flange
wrench
LC
NT771
EC
ST3090S000 Removing and installing drive pinion rear inner
( — ) cone FE
Drive pinion rear inner a: 79 mm (3.11 in) dia.
race puller set b: 45 mm (1.77 in) dia.
1 ST30031000 c: 35 mm (1.38 in) dia.
(J22912-01)
CL
Puller
2 ST30901000
(J26010-01) MT
Base NT527
AT
TF
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PD-3
Symptom
×: Applicable
Reference page
LER
Possible cause and
SHAFT
ENTIAL
DIFFER-
SUSPECTED PARTS
PROPEL-
Noise
Noise
Shake
Vibration
×
×
Uneven rotation torque —
×
×
×
Center bearing improper installation PD-6
NVH TROUBLESHOOTING CHART
×
×
Excessive center bearing axial end play —
×
×
Center bearing mounting (insulator) cracks, damage or deterioration —
×
×
×
Noise, Vibration and Harshness (NVH) Troubleshooting
Excessive joint angle —
×
×
Rotation imbalance PD-8
×
×
Excessive runout PD-8
PD-4
×
Rough gear tooth PD-24, 49, 73
×
Improper gear contact PD-31, 56, 83
×
Troubleshooting
Tooth surfaces worn PD-24, 49, 73
×
PROPELLER SHAFT
Incorrect backlash PD-20, 45, 69
×
Companion flange excessive runout —
×
Improper gear oil —
×
PROPELLER SHAFT Refer to PROPELLER SHAFT in this chart.
×
DIFFERENTIAL Refer to DIFFERENTIAL in this chart.
×
×
×
×
DRIVE SHAFT Refer to NVH, AX-4
×
×
×
×
AXLE Refer to NVH, AX-4
×
×
×
×
SUSPENSION Refer to NVH, SU-3
×
×
×
×
TIRES Refer to NVH, SU-3
×
×
×
ROAD WHEEL Refer to NVH, SU-3
×
×
×
BRAKES Refer to NVH, BR-8
×
×
×
×
STEERING Refer to NVH, ST-5
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
NEPD0049S01
=NEPD0049
PROPELLER SHAFT
Components
Components NEPD0002
FRONT PROPELLER SHAFT NEPD0002S01
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
WPD016
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PD-5
PROPELLER SHAFT
Components (Cont’d)
REAR PROPELLER SHAFT NEPD0002S02
WPD005
WPD017
PD-6
PROPELLER SHAFT
Components (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
WPD006
TF
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PD-7
PROPELLER SHAFT
On-vehicle Service
On-vehicle Service
PROPELLER SHAFT VIBRATION NEPD0003
If vibration is present at high speed, inspect propeller shaft runout
first.
1. Raise rear end of vehicle until wheels are clear of the ground.
2. Measure propeller shaft runout at several points along propel-
ler shaft by rotating final drive companion flange with hands.
Runout limit: 0.6 mm (0.024 in)
Propeller shaft runout measuring points:
SPD356A KA24DE engine
Unit: mm (in)
Distance A B C
A/T 226 485 —

3S1310 (King Cab)
M/T 274 485 —
3S1310 (Regular
A/T 226 336 —
Cab)
2S1310 (Regular
M/T 237 658 237
Cab)
VG33E engine
Unit: mm (in)
Distance A B C
A/T 241 491 —

3S1310 (2WD)
M/T 288 491 —
2S1310 (4WD) All 237 623.5 237
A/T 271 — —
2F1310 (4WD)
M/T 271 — —
WPD009
VG33ER engine
Unit: mm (in)
Distance A B C
3S80B-2BJ (Super-
All 162 240 240
charger)
3. If runout exceeds specifications, disconnect propeller shaft at

final drive companion flange; then rotate companion flange
180 degrees and reconnect propeller shaft.
4. Check runout again. If runout still exceeds specifications,
replace propeller shaft assembly.
5. Perform road test.
APPEARANCE CHECKING NEPD0004
쐌 Inspect propeller shaft tube surface for dents or cracks.
If damaged, replace propeller shaft assembly.
쐌 If center bearing is noisy or damaged, replace center bearing.
PD-8
PROPELLER SHAFT
Removal and Installation
Removal and Installation NEPD0005

1) Put match marks on flanges and separate propeller shaft from
final drive. GI
MA
EM
SPD103 LC
2) Remove propeller shaft.
Insert plug into rear oil seal after removing rear propeller
shaft. EC
FE
CL
SPD359
MT
Inspection NEPD0006
쐌 Inspect propeller shaft runout. If runout exceeds specifications, AT
replace propeller shaft assembly.
TF
AX
SPD106
쐌 If the play exceeds specifications, replace propeller shaft

assembly. SU
Journal axial play:
0.02 mm (0.0008 in) or less BR
ST
RS
SPD874
Disassembly NEPD0007
BT
CENTER BEARING NEPD0007S01
1. Put match marks on flanges, and separate 2nd tube from 1st HA
tube.
SC
EL
SPD109
IDX
PD-9
PROPELLER SHAFT
Disassembly (Cont’d)
2. Put match marks on the flange and shaft.
SPD110
3. Remove locking nut with Tool.

Tool number:
KV38108300 (J-44195)
4. Remove companion flange with puller.
SPD170A
5. Remove center bearing with Tool and press.

Tool number: ST30031000 (J22912-01)
SPD475A
JOURNAL NEPD0007S02
1. Put match marks on shaft and flange or yoke.
SPD128
2. Remove snap ring.
APD011
PD-10
PROPELLER SHAFT
3. Remove pushed out journal bearing by lightly tapping yoke
with a hammer, taking care not to damage journal and yoke
hole. GI
MA
EM
SPD732 LC
4. Remove bearing at opposite side in above operation.
Put marks on disassembled parts so that they can be rein- EC
stalled in their original positions from which they were
removed.
FE
CL
SPD131
MT
Assembly NEPD0008
CENTER BEARING AT
NEPD0008S01
쐌 When installing center bearing, position the “F” mark on cen-
ter bearing toward front of vehicle. TF
쐌 Apply a coat of multi-purpose lithium grease containing
molybdenum disulfide to the end face of the center bear-
ing and both sides of the washer.
AX
SPD114
쐌 Stake the nut. Always use a new one.

쐌 Align match marks when assembling tubes.
SU
BR
ST
RS
SPD117
JOURNAL NEPD0008S02
BT
1. Assemble journal bearing. Apply recommended multi-purpose
grease on bearing inner surface.
When assembling, be careful that needle bearing does not fall HA
down.
SC
EL
SPD133
IDX
PD-11
PROPELLER SHAFT
Assembly (Cont’d)
2. Install new snap rings.
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
PROPELLER SHAFT
Service Data and Specifications (SDS)

GENERAL SPECIFICATIONS =NEPD0009
GI
2WD KA24DE Models NEPD0009S01
Applied model Standard wheelbase Long wheelbase

MA
M/T A/T M/T A/T
Propeller shaft model
2S1310 3S1310
EM
Number of joints 2 3
Coupling method with transmission Sleeve type

LC
Type of journal bearings Solid type (disassembly type)
1st tube 1317 (51.85) 549.6 (21.64) 644.7 (25.38) 549.6 (21.64)
Shaft length (Spider to spider) mm (in) EC
2nd tube — 672 (26.46) 970.3 (38.20) 970.3 (38.20)
1st tube 88.9 (3.50) 63.5 (2.50) 63.5 (2.50) 63.5 (2.50)
Shaft diameter mm (in) FE
2nd tube — 63.5 (2.50) 63.5 (2.50) 63.5 (2.50)
2WD VG33E and VG33ER Models NEPD0009S03

CL
Grade XE, SE SC
Transmission M/T A/T M/T A/T MT

Propeller shaft model 3S1310 3S80B-2BJ
Number of joints 3 3
AT
Coupling method with transmission Sleeve type
Solid type (disassembly type with-

TF
out Birfield joint)
1st tube 661 (26.02) 566 (22.28) 681 (26.81) 586 (23.07)
Shaft length (Spider to spider) mm (in)
2nd tube 982.3 (38.67) 982.3 (38.67) 980 (38.58)
Shaft outer diameter mm (in)

1st tube 63.5 (2.50) 63.5 (2.50) 75 (2.95) AX
2nd tube 63.5 (2.50) 63.5 (2.50) 65 (2.56)
4WD Models SU
NEPD0009S04
Grade XE, SE SC
BR
Location Front Rear Front Rear
Propeller shaft model 2F1310 2S1310 2F1310 2S1310

ST
Number of joints 2 2 2 2
Coupling method with transmission Flange type Sleeve type Flange type Sleeve type
RS
Distance between yokes mm (in) 71 (2.80) 80 (3.15) 71 (2.80) 80 (3.15)

BT
Shaft length (Spider to spider) mm (in) 522 (20.55) 1247 (49.09) 522 (20.60) 1247 (49.09)
Shaft outer diameter mm (in) 50.8 (2.00) 76.2 (3.00) 50.8 (2.00) 88.9 (3.50)
HA
SERVICE DATA NEPD0010
Unit: mm (in)
SC
Propeller shaft runout limit 0.6 (0.024)
Journal axial play 0.02 (0.0008) or less

EL
IDX
PD-13
FRONT FINAL DRIVE R200A
Preparation
Preparation
SPECIAL SERVICE TOOLS NEPD0013
Tool number
(Kent-Moore No.) Description
Tool name
ST3127S000 Measuring pinion bearing preload and total preload

(See J25765-A)
Preload gauge
1 GG91030000
(J25765)
Torque wrench
2 HT62940000
( — )
Socket adapter
3 HT62900000 NT124
( — )
Socket adapter
KV38100800 Mounting final drive

(J34310, J25604-01) (To use, make a new hole.)
Differential attachment a: 152 mm (5.98 in)
NT119

Companion flange
wrench
NT771

( — ) cone
1 ST30031000 c: 35 mm (1.38 in) dia.
(J22912-01)
Puller
2 ST30901000
(J26010-01)
Base NT527
ST3306S001 Removing and installing differential side bearing

Differential side bearing inner cone
puller set a: 28.5 mm (1.122 in) dia.
1 ST33051001 b: 38 mm (1.50 in) dia.
(J22888-20)
Body
2 ST33061000
(J8107-2)
Adapter
NT072
KV38100300 Installing side bearing inner cone

(J25523) a: 54 mm (2.13 in) dia.
Differential side bearing b: 46 mm (1.81 in) dia.
drift c: 32 mm (1.26 in) dia.
NT085
PD-14
Preparation (Cont’d)
Tool number
Tool name GI
KV38100600 Installing side bearing spacer
(J25267) a: 8 mm (0.31 in) MA
Side bearing spacer b: R42.5 mm (1.673 in)
drift
NT528
EM
ST30611000 Installing pinion rear bearing outer race
(J25742-1) (Use with ST30621000 or ST30613000) LC
Drift
EC
NT090

(J25742-5) (Use with ST30611000) FE
Drift a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.
CL
NT073
ST30613000 Installing pinion front bearing outer race MT

(J25742-3) (Use with ST30611000)
b: 48 mm (1.89 in) dia. AT
NT073 TF
KV38100500 Installing front oil seal
(J25273) a: 85 mm (3.35 in) dia.
Gear carrier front oil b: 60 mm (2.36 in) dia.
seal drift
NT115
AX
KV38100200 Installing side oil seal
(J26233) SU
Gear carrier side oil
seal drift
BR
NT120
(J34309) Adjusting bearing pre-load and gear height

Differential shim selec- ST
tor
RS
BT
NT134 HA
(J25269-4) Selecting pinion height adjusting washer
Side bearing discs
(2 Req’d)
SC
NT136 EL
IDX
PD-15
Tool number
Tool name
(J8129) Measuring carrier turning torque

Spring gauge
NT127

Troubleshooting NEPD0050
Refer to “NVH TROUBLESHOOTING CHART”, PD-4.
On-vehicle Service
FRONT OIL SEAL REPLACEMENT NEPD0014
(Front final drive: Model R200A)
1. Remove front propeller shaft. Refer to “Removal and
Installation”, PD-9.
2. Loosen drive pinion nut.
Tool number: KV38108300 (J-44195)
SPD476A
3. Remove companion flange.
SPD734
4. Remove front oil seal.
SPD735
PD-16
On-vehicle Service (Cont’d)
5. Apply multi-purpose grease to cavity at sealing lips of oil seal.
Press front oil seal into carrier.
6. Install companion flange and drive pinion nut. GI
7. Install propeller shaft.
Tool number:
KV38100500 (J25273)
MA
EM
SPD736 LC
REAR COVER GASKET REPLACEMENT NEPD0015
1. Drain gear oil. EC
2. Remove rear cover and rear cover gasket.
3. Install new rear cover gasket and rear cover.
4. Fill final drive with recommended gear oil. FE
CL
SPD740-A
MT
AT
TF
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PD-17
Components
Components NEPD0016
WPD007
PD-18

REMOVAL
1) Remove front propeller shaft. Refer to “Removal and
NEPD0017S01
GI
2) Separate drive shaft from front final drive. Refer to AX-7, “Drive MA
Shaft”.
3) Remove engine mounting bolts and raise up engine.
4) Remove front final drive together with differential mounting EM
member.
CAUTION:
SPD741
Be careful not to damage spline, sleeve yoke and front oil seal LC
when removing propeller shaft.
Before removing the final drive assembly or rear axle
assembly, disconnect the ABS sensor harness connector from
EC
the assembly and move it away from the final drive/rear axle
assembly area. Failure to do so may result in the sensor wires FE
being damaged and the sensor becoming inoperative.
CL
MT
INSTALLATION NEPD0017S02
1) Install front final drive assembly together with differential AT
mounting member.
TF
AX
SPD742
2) Tighten front final drive securing bolts and nuts by following the
procedure to prevent drive train vibration. SU
a) Temporarily tighten nut A.
b) Temporarily tighten nut B. BR
c) Tighten bolt C to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
d) Tighten bolt D to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m, ST
50 to 64 ft-lb).
e) Tighten nut A to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m,
50 to 64 ft-lb). RS
f) Tighten nut B to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m,
50 to 64 ft-lb). BT
g) Tighten bolt E to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
3) Install drive shaft. Refer to AX-7, “Drive Shaft”. HA
4) Install front propeller shaft. Refer to “Removal and Installation”,
PD-9.
SC
EL
SPD743
IDX
PD-19
Disassembly
PRE-INSPECTION NEPD0018S01
Before disassembling final drive, perform the following inspection.
쐌 Total preload
a) Turn drive pinion in both directions several times to set bear-
ing rollers.
b) Check total preload with Tool.
Tool number: ST3127S000 (J25765-A)
Total preload:
SPD664 1.4 - 1.7 N·m (14 - 17 kg-cm, 12 - 15 in-lb)
쐌 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
쐌 Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit:
0.05 mm (0.0020 in)
쐌 Tooth contact
Check tooth contact. Refer to “TOOTH CONTACT”, PD-31.
SPD524
쐌 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 differ-
ential case:
Less than 0.15 mm (0.0059 in)
SPD665
FINAL DRIVE HOUSING NEPD0018S02

1. Using three spacers [20 mm (0.79 in)], mount final drive
assembly on Tool.
Tool number:
KV38100800 (J34310, J25604-01)
SPD666
PD-20
2. Remove differential side shaft assembly.
GI
MA
EM
SPD644 LC
3. Remove differential side flange.
EC
FE
CL
SPD667
MT
4. Put match marks on one side of side bearing cap with paint or
punch to ensure that it is replaced in proper position during AT
reassembly.
Bearing caps are line-bored during manufacture and should
be put back in their original places. TF
AX
SPD526
5. Remove side bearing caps.

SU
BR
ST
RS
PD343
6. Remove differential case assembly with a pry bar. BT
HA
SC
EL
SPD668
IDX
PD-21
Be careful to keep the side bearing outer races together with
their respective inner cones — do not 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: KV38108300 (J-44195)
SPD477A
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-22
DIFFERENTIAL CASE NEPD0018S03
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in grooves. GI
Tool number:
A ST33051001 (J22888-20) MA
B ST33061000 (J8107-2)
EM
SPD207A LC
Be careful not to confuse the right-hand and left-hand parts.
Keep bearing and bearing race for each side together.
EC
FE
CL
SPD022
MT
2. Loosen ring gear bolts in a crisscross pattern.
3. Tap ring gear off the differential case with a soft hammer. AT
Tap evenly all around to keep ring gear from binding.
TF
AX
SPD024
4. Punch off pinion mate shaft lock pin from ring gear side.
SU
BR
ST
RS
SPD025
DIFFERENTIAL SIDE SHAFT NEPD0018S04

BT
1. Cut collar with cold chisel. Be careful not to damage differen-
tial side shaft.
HA
SC
EL
SPD236A
IDX
PD-23
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
Inspection NEPD0019
RING GEAR AND DRIVE PINION NEPD0019S01
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).
PD-24
Inspection (Cont’d)
DIFFERENTIAL CASE ASSEMBLY NEPD0019S02
Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft and thrust washers. GI
MA
EM
SPD097AA LC
BEARING NEPD0019S03
1. Thoroughly clean bearing. EC
2. Check bearing for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner cone as a set. FE
CL
SPD715
MT
Adjustment NEPD0020
For quiet and reliable final drive operation, the following five adjust- AT
ments must be made correctly:
1. Side bearing preload. Refer to “SIDE BEARING PRELOAD”,
PD-25.
TF
2. Pinion gear height. Refer to “PINION GEAR HEIGHT AND
PINION BEARING PRELOAD”, PD-27.
3. Pinion bearing preload. Refer to “PINION GEAR HEIGHT AND
4. Ring gear-to-pinion backlash. Refer to “Total Preload AX
Adjustment”, PD-38.
5. Ring and pinion gear tooth contact pattern. Refer to “TOOTH
CONTACT”, PD-31. SU
BR
ST
RS
SIDE BEARING PRELOAD NEPD0020S01

BT
A selection of carrier side bearing adjusting washers is
required for successful completion of this procedure.
1. Make sure all parts are clean and that the bearings are well HA
lubricated with light oil or “DEXRONTM” type automatic trans-
mission fluid.
2. Place the differential carrier, with side bearings and bearing
SC
races installed, into the final drive housing.
EL
SPD527
IDX
PD-25
Adjustment (Cont’d)
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
5. Install the side bearing caps in their correct locations and

torque the bearing cap retaining bolts.
Specification:
88 - 98 N·m (9 - 10 kg-m, 65 - 72 ft-lb)
6. Turn the carrier several times to seat the bearings.
SPD526
7. Measure the turning torque of the carrier at the ring gear retain-
ing bolts with a spring gauge, J8129.
Specification:
34.3 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb) of pulling force
at the ring gear bolt
SPD194A
8. If the carrier turning torque is not within the specification range,

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
of greater thickness; if the turning torque is greater than the
specification, install thinner washers. Refer to “Side Bearing
Adjustment”, PD-38 for washer dimensions and part numbers.
9. Record the total amount of washer thickness required for the
correct carrier side bearing preload.
SPD772
PD-26
10. Remove the carrier from the final drive housing, saving the
selected preload washers for later use during the assembly of
the final drive unit. GI
MA
EM
SPD668 LC
PINION GEAR HEIGHT AND PINION BEARING
PRELOAD NEPD0020S02 EC
1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion gear bearings into the pinion preload shim FE
selector Tool, J34309.
CL
SPD769
MT
쐌 Front Pinion Bearing — make sure the J34309-3 front pinion
bearing seat is secured tightly against the J34309-2 gauge AT
anvil. Then turn the front pinion bearing pilot, J34309-5, to
secure the bearing in its proper position.
쐌 Rear Pinion Bearing — the rear pinion bearing pilot, J34309- TF
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.
AX
SPD197A
3. Place the pinion preload shim selector Tool, J34309-1, gauge

screw assembly with the pinion rear bearing inner cone SU
installed into the final drive housing.
BR
ST
RS
SPD893
4. Assemble the front pinion bearing inner cone and the J34309-2 BT
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 HA
two sections together by hand.
SC
EL
SPD199A
IDX
PD-27
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 N·m (10 - 13 kg-cm, 8.7 - 11.3 in-lb)
SPD234A
7. Place the J34309-1 “R200A” pinion height adapter onto the

gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.
SPD208A
PINION BEARING PRELOAD WASHER SELECTION

8. Place the solid pinion bearing spacer, small end first, over the
J34309-2 gauge anvil and seat the small end squarely against
the tip of the J34309-1 gauge screw in the tool recessed por-
tion.
SPD209A
SPD773
PD-28
9. Select the correct thickness of pinion bearing preload adjust-
ing washer using a standard gauge of 3.5 mm (0.138 in) and
J34309-101 feeler gauge. The exact measure is the thickness GI
of the adjusting washer required. Select the correct washer.
Drive pinion bearing preload adjusting washer:
Refer to “Drive Pinion Preload Adjustment”, PD-39. MA
10. Set the selected, correct pinion bearing preload adjusting
washer aside for use when assembling the pinion gear and
bearings into the final drive. EM
SPD210A LC
EC
FE
CL
SPD774
MT
PINION HEIGHT ADJUSTING WASHER SELECTION
11. Position the side bearing discs, J25269-4, and arbor firmly into AT
the side bearing bores.
TF
AX
SPD211A
12. Install the side bearing caps and tighten the cap bolts.
Specification:
SU
88 - 98 N·m (9 - 10 kg-m, 65 - 72 ft-lb)
BR
ST
RS
SPD212A
13. Select the correct standard pinion height adjusting washer BT

thickness by using a standard gauge of 3.0 mm (0.118 in) and
J34309-101 feeler gauge. Measure the gap between the
J34309-11 “R200A” pinion height adapter and the arbor. HA
14. Write down the exact total measurement.
SC
EL
SPD204A
IDX
PD-29
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.
Use the following chart to determine the correct pinion height
washer. Refer to “Drive Pinion Height Adjustment”, PD-39.
Add or Remove from the Standard
SPD542 Pinion Head Height Number Pinion Height Washer Thickness
Measurement
−6 Add 0.06 mm (0.0024 in)
−5 Add 0.05 mm (0.0020 in)
−4 Add 0.04 mm (0.0016 in)
−3 Add 0.03 mm (0.0012 in)
−2 Add 0.02 mm (0.0008 in)
−1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)
16. Select the correct drive pinion height washer.

Drive pinion height adjusting washer:
Refer to “Drive Pinion Height Adjustment”, PD-39.
17. Remove the J34309 pinion preload shim selector tool from the
final drive housing and disassemble to retrieve the pinion
bearings.
SPD205A
PD-30
TOOTH CONTACT =NEPD0020S03

Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion. GI
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 MA
life can be assured.
EM
LC
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.
EC
FE
CL
SPD357
MT
3. Hold companion flange steady by hand and rotate the ring gear
in both directions. AT
TF
AX
SPD677
SU
BR
ST
RS
BT
HA
SC
SPD007-B
EL
IDX
PD-31
Assembly
Assembly NEPD0021
DIFFERENTIAL SIDE SHAFT NEPD0021S01
1. Install oil seal and grease seal.
SPD782-A
SPD654-A
2. Install extension tube retainer, rear axle bearing and rear axle
shaft bearing collar on differential side shaft.
SPD655

1. Install side gears, pinion mate gears and thrust washers into
differential case.
SPD552
2. Fit pinion mate shaft to differential case so that it meets lock

pin holes.
3. Adjust backlash between side gear and pinion mate gear by
selecting side gear thrust washer.
Refer to “Side Gear Adjustment”, PD-38.
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and differ-
ential case):
SPD258
PD-32
Assembly (Cont’d)
4. Install pinion mate shaft lock pin with a punch.
Make sure lock pin is flush with case.
GI
MA
EM
SPD030 LC
5. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see they turn properly.
EC
FE
CL
SPD322
MT
6. Install differential case assembly on ring gear.
7. Apply locking agent [Locktite (stud lock) or equivalent] to ring AT
gear bolts, and install them.
Tighten bolts in a crisscross pattern.
TF
AX
SPD554
8. Press-fit side bearing inner cones on differential case with Tool.

Tool number:
SU
A KV38100300 (J25523)
B ST33061000 (J8107-2) BR
ST
RS
PD353
BT
HA
SC
EL
IDX
PD-33
Assembly (Cont’d)
FINAL DRIVE HOUSING NEPD0021S03
1. Press-fit front and rear bearing outer races with Tools.
Tool number:
A ST30611000 (J25742-1)
B ST30621000 (J25742-5)
C ST30613000 (J25742-3)
SPD679
2. Select drive pinion height adjusting washer and pinion bearing

adjusting washer. Refer to “PINION GEAR HEIGHT AND PIN-
ION BEARING PRELOAD”, PD-27.
3. Install drive pinion height adjusting washer in drive pinion, and
press-fit pinion rear bearing inner cone in it, using press and
Tool.
Tool number:
ST30901000 (J26010-01)
SPD377
4. Place pinion front bearing inner cone in final drive housing.
SPD581

Install front oil seal.
Tool number:
KV38100500 (J25273)
SPD680
PD-34
Assembly (Cont’d)
6. Place drive pinion bearing spacer, drive pinion bearing adjust-
ing washer and drive pinion in final drive housing.
GI
MA
EM
SPD658 LC
7. Insert companion flange into drive pinion by tapping the com-
panion flange with a soft hammer.
EC
FE
CL
SPD681
MT
8. Tighten pinion nut to the specified torque.
The threaded portion of drive pinion and pinion nut should be AT
free from oil or grease.
Tool number: KV38108300 (J-44195)
TF
AX
SPD478A
9. Turn drive pinion in both directions several revolutions, and

measure pinion bearing preload. SU
Pinion bearing preload: BR
1.1 - 1.4 N·m (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 ST
different thickness.
RS
SPD664
10. Select side bearing adjusting washer. BT

Refer to “SIDE BEARING PRELOAD”, PD-25.
11. Install differential case assembly with side bearing outer races
into final drive housing. HA
SC
EL
SPD527
IDX
PD-35
Assembly (Cont’d)
12. Insert left and right side bearing adjusting washers in place
between side bearings and final drive housing.
SPD558
13. Drive in side bearing spacer with Tool.

SPD559
14. Align mark on bearing cap with that on final drive housing and
install bearing cap on final drive housing.
SPD526

Install side oil seal.
SPD560
16. Measure ring gear to drive pinion backlash with a dial indica-
tor.
0.10 - 0.15 mm (0.0039 - 0.0059 in)
쐌 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.
Never change the total amount of shims as it will change the
bearing preload.
SPD513
PD-36
Assembly (Cont’d)
17. Check total preload with Tool.
When checking preload, turn drive pinion in both direc-
tions several times to set bearing rollers. GI
Total preload:
1.4 - 1.7 N·m (14 - 17 kg-cm, 12 - 15 in-lb) MA
EM
SPD664 LC
쐌 If preload is too great, remove the same amount of shim from
each side.
쐌 If preload is too small, add the same amount of shim to each
EC
side.
Never add or remove a different number of shims for each side FE
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 CL
gear-to-pinion backlash.
SPD561
MT
19. Check runout of ring gear with a dial indicator.
Runout limit: AT
0.05 mm (0.0020 in)
쐌 If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the ring TF
gear and the differential case.
쐌 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 “TOOTH CONTACT”, PD-31. AX
SPD524 21. Install rear cover and gasket.
22. Install differential side shaft assembly.
SU
BR
ST
RS
SPD682
BT
HA
SC
EL
IDX
PD-37

R200A
General Specifications =NEPD0022
Engine VG33E VG33ER
Vehicle grade XE SE SC
R200A
Front final drive
2-pinion
Gear ratio 4.636 4.900 4.363
Number of teeth (Ring gear/drive pinion) 51/11 49/10 48/11
Oil capacity (Approx.) (US pt, lmp pt) 1.5 (3-1/8, 3-5/8)
Ring Gear Runout NEPD0023
Ring gear runout limit mm (in) 0.05 (0.0020)
Side Gear Adjustment NEPD0024
Side gear backlash (Clearance between side gear and differential case) mm
Less than 0.15 (0.0059)
(in)
Thickness mm (in) Part number*
0.75 (0.0295) 38424-N3110

Available side 0.78 (0.0307) 38424-N3111
gear thrust 0.81 (0.0319) 38424-N3112
washers 0.84 (0.0331) 38424-N3113
0.87 (0.0343) 38424-N3114
0.90 (0.0354) 38424-N3115
0.93 (0.0366) 38424-N3116
*Always check with the Parts Department for the latest parts information.
Side Bearing Adjustment NEPD0025
Differential carrier assembly turning resistance N (kg, lb) 34.3 - 39.2 (3.5 - 4.0, 7.7 - 8.8)
2.00 (0.0787) 38453-N3100

2.05 (0.0807) 38453-N3101
2.10 (0.0827) 38453-N3102
2.15 (0.0846) 38453-N3103
Available side 2.20 (0.0866) 38453-N3104
bearing adjust- 2.25 (0.0886) 38453-N3105
ing washers 2.30 (0.0906) 38453-N3106
2.35 (0.0925) 38453-N3107
2.40 (0.0945) 38453-N3108
2.45 (0.0965) 38453-N3109
2.50 (0.0984) 38453-N3110
2.55 (0.1004) 38453-N3111
2.60 (0.1024) 38453-N3112
Total Preload Adjustment NEPD0026
Total preload N·m (kg-cm, in-lb) 1.4 - 1.7 (14 - 17, 12 - 15)
Ring gear to pinion backlash mm (in) 0.10 - 0.15 (0.0039 - 0.0059)
PD-38
Service Data and Specifications (SDS) (Cont’d)
Drive Pinion Height Adjustment NEPD0027

GI
3.09 (0.1217) 38154-P6017
3.12 (0.1228) 38154-P6018
3.15 (0.1240) 38154-P6019 MA
3.18 (0.1252) 38154-P6020
3.21 (0.1264) 38154-P6021
3.24 (0.1276) 38154-P6022
3.27 (0.1287) 38154-P6023 EM
Available pin- 3.30 (0.1299) 38154-P6024
ion height 3.33 (0.1311) 38154-P6025
adjusting 3.36 (0.1323) 38154-P6026 LC
washers 3.39 (0.1335) 38154-P6027
3.42 (0.1346) 38154-P6028
3.45 (0.1358) 38154-P6029
3.48 (0.1370) 38154-P6030 EC
3.51 (0.1382) 38154-P6031
3.54 (0.1394) 38154-P6032
3.57 (0.1406) 38154-P6033
3.60 (0.1417) 38154-P6034
FE
3.63 (0.1429) 38154-P6035
3.66 (0.1441) 38154-P6036
CL
Drive Pinion Preload Adjustment NEPD0028 MT

Drive pinion bearing preload adjusting method Adjusting washer and spacer
Drive pinion preload with front oil seal N·m (kg-cm, in-lb) 1.1 - 1.4 (11 - 14, 9.5 - 12.2)
AT
3.81
3.83
(0.1500)
(0.1508)
38125-61001
38126-61001
TF
3.85 (0.1516) 38127-61001
3.87 (0.1524) 38128-61001
3.89 (0.1531) 38129-61001
Available drive
3.91 (0.1539) 38130-61001
pinion bearing
3.93 (0.1547) 38131-61001
preload adjust-
3.95 (0.1555) 38132-61001
ing washers
3.97 (0.1563) 38133-61001
AX
3.99 (0.1571) 38134-61001
4.01 (0.1579) 38135-61001
4.03 (0.1587) 38136-61001 SU
4.05 (0.1594) 38137-61001
4.07 (0.1602) 38138-61001
4.09 (0.1610) 38139-61001
BR
Length mm (in) Part number*
Available drive 54.50 (2.1457) 38165-B4000

pinion bearing 54.80 (2.1575) 38165-B4001 ST
preload adjust- 55.10 (2.1693) 38165-B4002
ing spacers 55.40 (2.1811) 38165-B4003
55.70 (2.1929) 38165-B4004 RS
56.00 (2.2047) 38165-61001
BT
HA
SC
EL
IDX
PD-39
REAR FINAL DRIVE C200
Preparation
Preparation
Tool number
Tool name

(See J25765-A)
Preload gauge
1 GG91030000
(J25765)
Torque wrench
2 HT62940000
( — )
Socket adapter
3 HT62900000 NT124
( — )
Socket adapter
KV38108300 Removing and installing propeller shaft lock nut

(J44195) and drive pinion lock nut
Companion flange
wrench
NT771

( — ) cone
1 ST30031000 c: 35 mm (1.38 in) dia.
(J22912-01)
Puller
2 ST30901000
(J26010-01)
Base NT527

1 ST33051001 b: 38 mm (1.50 in) dia.
(J22888-20)
Body
2 ST33061000
(J8107-2)
Adapter
NT072
ST33230000 Installing side bearing inner cone

(J25805-01) a: 51 mm (2.01 in) dia.
Differential side bearing b: 41 mm (1.61 in) dia.
drift c: 28.5 mm (1.122 in) dia.
NT085

( — ) a: 43 mm (1.69 in) dia.
Side bearing puller b: 33.5 mm (1.319 in) dia.
adapter
NT431
PD-40
Tool number
Tool name GI
KV38100600 Installing side bearing spacer
(J25267) a: 8 mm (0.31 in) MA
Side bearing spacer drift b: R42.5 mm (1.673 in)
NT528
EM
(J25742-1) LC
Drift
EC
NT090

(J25742-5) a: 79 mm (3.11 in) dia. FE
Drift b: 59 mm (2.32 in) dia.
CL
NT073
ST30613000 Installing pinion front bearing outer race MT

(J25742-3) a: 72 mm (2.83 in) dia.
AT
NT073 TF
(J25273) a: 85 mm (3.35 in) dia.
seal drift
NT115
AX
Differential shim selec- SU
tor
BR
ST
NT134 RS
Side bearing discs
(2 Req’d) BT
NT136
HA
(J8129) Measuring carrier turning torque
Spring gauge
SC
NT127 EL
IDX
PD-41
Tool number
Tool name
KV381051S0 Checking differential torque on limited slip differen-

( — ) tial
Rear axle shaft dummy
1 KV38105110
( — )
Torque wrench side
2 KV38105120
NT142
( — )
Vise side

PD-42
On-vehicle Service
On-vehicle Service
FRONT OIL SEAL REPLACEMENT
1.
=NEPD0124
Remove propeller shaft. Refer to “Removal and Installation”,
GI
PD-9.
2. Loosen drive pinion nut. MA
Tool number: KV38108300 (J-44195)
EM
APD032 LC
4. Remove ABS sensor and sensor rotor.
EC
FE
CL
SPD737
MT
AT
TF
AX
WPD013

Press front oil seal into carrier. SU
Tool number:
KV38100500 (J25273) BR
7. Install ABS sensor and sensor rotor.
8. Install companion flange and drive pinion nut.
9. Install rear propeller shaft. ST
RS
WPD014
REAR COVER GASKET REPLACEMENT NEPD0116

BT
(Rear final drive: Model C200)
1. Drain gear oil.
HA
3. Install new rear cover gasket and rear cover.
4. Fill final drive with recommended gear oil. SC
EL
SPD740-A
IDX
PD-43
Components
Components NEPD0117
WPD018
PD-44

REMOVAL
쐌
NEPD0118S01
GI
PD-9.
Plug front end of transfer. MA
쐌 Remove axle shaft.
Refer AX-30, “REAR AXLE”.
CAUTION: EM
쐌 Be careful not to damage spline, sleeve yoke and front oil
seal when removing propeller shaft.
쐌 Before removing the final drive assembly or rear axle LC
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 EC
sensor wires being damaged and the sensor becoming
inoperative.
FE
CL
MT
쐌 Fill final drive with recommended gear oil. AT
TF
AX
SPD123
Disassembly NEPD0119 SU
Before disassembling final drive, perform the following inspection.
쐌 Total preload BR
a) Turn drive pinion in both directions several times to set bear-
ing rollers.
ST
Total preload: RS
PD245 1.2 - 2.3 N·m (12 - 23 kg-cm, 10 - 20 in-lb)
쐌 Ring gear-to-drive pinion backlash. BT
points.
Ring gear-to-drive pinion backlash: HA
0.13 - 0.18 mm (0.0051 - 0.0071 in)
SC
EL
SPD196
IDX
PD-45
SPD702
쐌 Tooth contact
쐌 Side gear-to-pinion mate gear backlash
Measure clearance between side gear thrust washer and dif-
ferential case with a feeler gauge.
ential case:
SPD198
DIFFERENTIAL CARRIER NEPD0119S02

punch to ensure that it is replaced in proper position during
reassembly.
be put back in their original places.
SPD714
3. Remove side bearing caps.
SPD202
4. Remove differential case assembly with pry bar.
SPD193
PD-46
Keep the side bearing outer races together with their respec-
tive inner cones — do not mix them up.
GI
MA
EM
SPD745 LC
5. Remove pinion nut with Tool.
EC
FE
CL
APD032
MT
7. Remove ABS sensor and sensor rotor. AT
TF
AX
SPD014
8. Remove drive pinion with soft hammer.

SU
BR
ST
RS
SPD206
10. Remove pinion bearing outer races with a brass drift. BT
HA
SC
EL
PD349
IDX
PD-47
11. Remove pinion rear bearing inner cone and pinion height
adjusting washer.
Tool number: ST30031000 (J22912-01)
PD179

To prevent damage to bearing, engage puller jaws in
grooves.
Tool numbers:
A ST33051001 (J22888-20)
B ST33061000 (J8107-2)
SPD529
Be careful not to confuse the right-hand and left-hand parts.
SPD022
2. Loosen ring gear bolts in a crisscross fashion.

3. Tap ring gear off the differential case with a soft hammer.
SPD024
PD-48
4. Punch off pinion mate shaft lock pin from ring gear side.
Lock pin is caulked at pinhole mouth on differential case.
GI
MA
EM
SPD025 LC
Inspection NEPD0120
RING GEAR AND DRIVE PINION NEPD0120S01
EC
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). FE
CL
MT
Check mating surfaces of differential case, side gears, pinion mate AT
gears, pinion mate shaft, thrust block and thrust washers.
TF
AX
SPD584
BEARING
1. Thoroughly clean bearing.
NEPD0120S03 SU
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged, BR
replace outer race and inner cone as a set.
ST
RS
SPD715
Adjustment NEPD0121
BT
For quiet and reliable final drive operation, the following five adjust-
ments must be made correctly.
1. Side bearing preload. Refer to “SIDE BEARING PRELOAD”,
HA
PD-50.
2. Pinion gear height. Refer to “PINION GEAR HEIGHT AND SC
3. Pinion bearing preload. Refer to “PINION GEAR HEIGHT AND
PINION BEARING PRELOAD”, PD-51. EL
4. Ring gear-to-pinion backlash. Refer to “Total Preload
IDX
PD-49
CONTACT”, PD-56.
SIDE BEARING PRELOAD NEPD0121S01
A selection of carrier side bearing preload shims is required
for successful completion of this procedure.
1. Make sure all parts are clean. Make sure, also, the bearings
are well lubricated with light oil or type “DEXRONTM” automatic
transmission fluid.
2. Place the differential carrier, with side bearings and bearing
races installed, into the final drive housing.
SPD919
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. Use Tool to place original carrier side bearing preload shims on

the carrier end, opposite the ring gear.
SPD986
5. Install the side bearing caps in their correct locations and

torque the bearing cap retaining bolts.
Specification:
88 - 98 N·m (9.0 - 10.0 kg-m, 65 - 72 ft-lb)
6. Turn the carrier several times to seat the bearings.
SPD526
PD-50
7. Measure the turning torque of the carrier at the ring gear retain-
ing bolts with a spring gauge, J8129.
Specification: GI
34.3 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb) of pulling force
at the ring gear bolt
MA
EM
SPD194A LC
8. If the turning torque is not within the specifications, correct the
torque as follows:
쐌 If the turning torque is less than the specified range, install
EC
washers of greater thickness.
쐌 If the turning torque is greater than the specification, install FE
thinner washers.
쐌 Refer to “Side Bearing Adjustment”, PD-62, for washer dimen-
sions and part numbers. CL
9. Record the total amount of washer thickness required for the
correct carrier side bearing preload.
SPD772
MT
10. Remove the carrier from the final drive housing. Save the
selected preload washers for later use during the assembly of AT
the final drive unit.
TF
AX
PD344
PINION GEAR HEIGHT AND PINION BEARING

PRELOAD SU
NEPD0121S02
lubricated. BR
2. Assemble the pinion gear bearings into the pinion preload shim
selector Tool, J34309.
ST
RS
SPD769
쐌 Front pinion bearing — make sure the J34309-3 front pinion BT

bearing seat is secured tightly against the J34309-2 gauge
secure the bearing in its proper position. HA
쐌 Rear pinion bearing — the rear pinion bearing pilot,
J34309-8, is used to center the rear pinion bearing only. The
rear pinion bearing locking seat, J34309-4, is used to lock the SC
bearing to the assembly.
EL
SPD197A
IDX
PD-51
3. Install the pinion rear bearing inner cone into the final drive
housing. Then place the pinion preload shim selector Tool,
J34309-1, on gauge screw assembly.
SPD893
4. Assemble the front pinion bearing inner cone and the J34309-2
gauge anvil. Assemble them 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.
Tighten the two sections together by hand.
SPD199A
SPD770

anvil using Tool.
1.0 - 1.3 N·m (10 - 13 kg-cm, 8.7 - 11.3 in-lb)
SPD234A
7. Place the J34309-11 pinion height adapter onto the gauge

plate and tighten it by hand.
CAUTION:
SPD208A
PD-52
PINION BEARING PRELOAD WASHER SELECTION
8. Place the solid pinion bearing spacer, small end first, over the
J34309-2 gauge anvil and seat the small end squarely against GI
the tip of the J34309-1 gauge screw in the tool recessed por-
tion.
MA
EM
SPD209A LC
EC
FE
CL
SPD773
MT
9. Select the correct thickness of pinion bearing preload adjust-
ing washer using a standard gauge of 3.5 mm (0.138 in) and AT
J34309-101 feeler gauge. The exact measure is the thickness
of the adjusting washer required. Select the correct washer.
Drive pinion bearing preload adjusting washer: TF
Refer to “Drive Pinion Preload Adjustment”, PD-63.
10. Set the selected, correct pinion bearing preload adjusting
washer aside for use when assembling the pinion gear and
bearings into the final drive.
AX
SPD210A
SU
BR
ST
RS
SPD774
PINION HEIGHT ADJUSTING WASHER SELECTION BT

11. Now, position the side bearing discs, J25269-4, and arbor
firmly into the side bearing bores.
Install the side bearing caps and tighten the cap bolts to proper HA
torque.
SC
EL
SPD211A
IDX
PD-53
12. Select the correct standard pinion height adjusting washer
thickness. Select by using a standard gauge of 3 mm (0.12 in)
and J34309-101 feeler gauge. Measure the distance between
the J34309-11 pinion height adapter including the standard
gauge and the arbor.
13. Write down the exact measurement (the value of feeler gauge).
SPD204A
14. 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. This number should be the same as the number on the
ring gear. The second number is the “pinion head height
number”. It refers to the ideal pinion height from standard
for quietest operation. Use the following chart to deter-
mine the correct pinion height washer.
Use the following chart to determine the correct pinion height
washer:
SPD542
Add or remove from the standard
Pinion head height number pinion height washer thickness
measurement
−6 Add 0.06 mm (0.0024 in)
−5 Add 0.05 mm (0.0020 in)
−4 Add 0.04 mm (0.0016 in)
−3 Add 0.03 mm (0.0012 in)
−2 Add 0.02 mm (0.0008 in)
−1 Add 0.01 mm (0.0004 in)
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)
15. Select the correct pinion height washer.

Drive pinion height adjusting washer:
PD-54
16. Remove the J34309 pinion preload shim selector Tool from the
final drive housing. Then disassemble to retrieve the pinion
bearings. GI
MA
EM
SPD205A LC
EC
FE
CL
MT
AT
TF
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PD-55

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

SPD199
3. Hold companion flange steady and rotate the ring gear in both
directions.
SPD200
SPD007-B
PD-56
Assembly
Assembly NEPD0122
DIFFERENTIAL CASE
1. Measure clearance between side gear thrust washer and dif-
NEPD0122S01
GI
ferential case.
Clearance between side gear thrust washer and differ- MA
ential case (A – B):
The clearance can be adjusted with side gear thrust washer. EM
check to see that they turn properly. LC
EC
FE
CL
SPD656
MT
3. Install differential case LH and RH.
AT
TF
AX
SPD643
4. Place differential case on ring gear.

5. Apply locking agent [Locktite (stud lock) or equivalent] to ring
SU
gear bolts, and install them.
BR
ST
RS
SPD746
6. Press-fit side bearing inner cones on differential case with Tool. BT

Tool numbers:
A ST33230000 (J25805-01)
B ST33061000 (J8107-2) HA
SC
EL
PD353
IDX
PD-57
Assembly (Cont’d)
Tool numbers:
A ST30611000 (J25742-1)
B ST30621000 (J25742-5)
C ST30613000 (J25742-3)
SPD679
2. Select pinion height adjusting washer. Refer to “PINION GEAR

HEIGHT AND PINION BEARING PRELOAD”, PD-51.
3. Install pinion height adjusting washer in drive pinion, and
press-fit 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

SPD557
PD-58
Assembly (Cont’d)
6. Place drive pinion bearing spacer, drive pinion bearing adjust-
ing washer and drive pinion in gear carrier.
GI
MA
EM
SPD222 LC
7. Install ABS sensor, sensor rotor, and companion flange onto
drive pinion. Tap the companion flange with a soft hammer until
fully seated. EC
FE
CL
SPD708
MT
8. Tighten pinion nut to 127 N·m (13 kg-m, 94 ft-lb).
The threaded portion of drive pinion and pinion nut should AT
be free from oil or grease.
TF
AX
APD032
9. Tighten the pinion nut by very small degrees until the specified
preload is achieved. When checking the preload, turn the drive SU
pinion in both directions several times to set the bearing roll-
ers.
BR
Pinion bearing preload:
1.1 - 1.7 N·m (11 - 17 kg-cm, 9.5 - 14.8 in-lb) ST
This procedure will have to be repeated if:
쐌 Maximum preload is achieved before the minimum pinion
nut torque is reached. RS
SPD241 쐌 Minimum preload is not achieved before maximum pinion
nut torque is reached. BT
10. Select side bearing adjusting washer.
Refer to “SIDE BEARING PRELOAD”, PD-50.
11. Install differential case assembly with side bearing outer races HA
into gear carrier.
SC
EL
SPD203
IDX
PD-59
Assembly (Cont’d)
12. Insert left and right side bearing adjusting washers in place
between side bearing and carrier.
SPD558
13. Drive in side bearing spacer with Tool.

SPD709
14. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.
SPD226
15. Measure ring gear-to-drive pinion backlash with a dial indica-

tor.
0.13 - 0.18 mm (0.0051 - 0.0071 in)
쐌 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.
Never change the total amount of shims as it will change the
bearing preload.
SPD196
16. Check total preload with Tool.

When checking preload, turn drive pinion in both direc-
tions several times to seat bearing rollers correctly.
Total preload:
1.2 - 2.3 N·m (12 - 23 kg-cm, 10 - 20 in-lb)
SPD241
PD-60
Assembly (Cont’d)
쐌 If preload is too great, remove the same amount of shim from
each side.
쐌 If preload is too small, add the same amount of shim to each GI
side.
Never add or remove a different number of shims for each side
as it will change ring gear-to-drive pinion backlash. MA
17. Recheck ring gear-to-drive pinion backlash because increase
or decrease in thickness of shims will cause change of ring
gear-to-pinion backlash.
EM
SPD561 LC
18. Check runout of ring gear with a dial indicator.
EC
may have resulted from foreign matter caught between the ring
gear and the differential case. FE
is within a specified range, the hypoid gear set or differential
case should be replaced. CL
19. Check tooth contact.
Refer to “TOOTH CONTACT”, PD-56.
SPD702 20. Install rear cover and gasket. MT
AT
TF
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PD-61

C200 =NEPD0123
General Specifications NEPD0123S01
Engine KA24DE
Body Standard wheelbase Long wheelbase
Transmission A/T M/T A/T M/T
Standard
Rear final drive C200
2-pinion
Gear ratio 4.111 3.700 4.625 3.900
Number of teeth (Ring gear/drive pinion) 37/9 37/10 37/8 39/10
Oil capacity (Approx.) (US pt, lmp pt) 1.3 (2-3/4, 2-1/4)
Ring Gear Runout NEPD0123S02
Side Gear Adjustment NEPD0123S03
Less than 0.15 (0.0059)
(in)
0.75 (0.0295) 38424-N3110

Available side 0.78 (0.0307) 38424-N3111
gear thrust 0.81 (0.0319) 38424-N3112
washers 0.84 (0.0331) 38424-N3113
0.87 (0.0343) 38424-N3114
0.90 (0.0354) 38424-N3115
0.93 (0.0366) 38424-N3116
Side Bearing Adjustment NEPD0123S04
Differential carrier assembly turning resistance N (kg, lb) 34.3 - 39.2 (3.5 - 4.0, 7.7 - 8.8)
2.00 (0.0787) 38453-N3100

2.05 (0.0807) 38453-N3101
2.10 (0.0827) 38453-N3102
2.15 (0.0846) 38453-N3103
Available side 2.20 (0.0866) 38453-N3104
bearing adjust- 2.25 (0.0886) 38453-N3105
ing washers 2.30 (0.0906) 38453-N3106
2.35 (0.0925) 38453-N3107
2.40 (0.0945) 38453-N3108
2.45 (0.0965) 38453-N3109
2.50 (0.0984) 38453-N3110
2.55 (0.1004) 38453-N3111
2.60 (0.1024) 38453-N3112
Total Preload Adjustment NEPD0123S05
Ring gear-to-pinion backlash mm (in) 0.13 - 0.18 (0.0051 - 0.0071)
PD-62
Drive Pinion Height Adjustment NEPD0123S06

GI
3.09 (0.1217) 38154-P6017
3.12 (0.1228) 38154-P6018
3.15 (0.1240) 38154-P6019 MA
3.18 (0.1252) 38154-P6020
3.21 (0.1264) 38154-P6021
3.24 (0.1276) 38154-P6022
3.27 (0.1287) 38154-P6023 EM
Available pin- 3.30 (0.1299) 38154-P6024
ion height 3.33 (0.1311) 38154-P6025
adjusting 3.36 (0.1323) 38154-P6026 LC
washers 3.39 (0.1335) 38154-P6027
3.42 (0.1346) 38154-P6028
3.45 (0.1358) 38154-P6029
3.48 (0.1370) 38154-P6030 EC
3.51 (0.1382) 38154-P6031
3.54 (0.1394) 38154-P6032
3.57 (0.1406) 38154-P6033
3.60 (0.1417) 38154-P6034
FE
3.63 (0.1429) 38154-P6035
3.66 (0.1441) 38154-P6036
CL
Drive Pinion Preload Adjustment NEPD0123S07 MT

Drive pinion bearing preload adjusting method Collapsible spacer
Drive pinion preload with front oil seal N·m (kg-cm, in-lb) 1.1 - 1.7 (11 - 17, 9.5 - 15)
AT
Drive pinion preload without front oil seal N·m (kg-cm, in-lb) 1.0 - 1.6 (10 - 16, 8.7 - 14)
TF
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PD-63
REAR FINAL DRIVE H233B
Preparation
Preparation
Tool number
Tool name

(See J25765-A)
Preload gauge
1 GG91030000
(J25765)
Torque wrench
2 HT62940000
( — )
Socket adapter
3 HT62900000 NT124
( — )
Socket adapter
ST06340000 Mounting final drive

(J24310, J34310)
Differential attachment
NT140
ST32580000 Adjusting side bearing preload and backlash (ring

(J34312) gear-drive pinion)
Differential side bearing
adjusting nut wrench
NT141

Companion flange
wrench
NT771

( — ) cone
1 ST30031000 c: 35 mm (1.38 in) dia.
(J22912-01)
Puller
2 ST30901000
(J26010-01)
Base NT527

1 ST33051001 b: 38 mm (1.50 in) dia.
(J22888-20)
Body
2 ST33061000
(J8107-2)
Adapter
NT072
PD-64
Tool number
Tool name GI
(J25523) a: 52 mm (2.05 in) dia. MA
Differential side bearing b: 45.5 mm (1.791 in) dia.
drift c: 34 mm (1.34 in) dia.
EM
NT085
ST33081000 Installing side bearing inner cone LC

( — ) a: 43 mm (1.69 in) dia.
Side bearing puller b: 33.5 mm (1.319 in) dia.
adapter EC
NT431 FE
(J25742-1) (Use with ST30621000 or ST30613000)
Drift CL
NT090
MT
(J25742-5) a: 79 mm (3.11 in) dia. AT
TF
NT073
ST30613000 Installing pinion front bearing outer race

(J25742-3) (Use with ST30611000)
b: 48 mm (1.89 in) dia. AX
NT073
SU
KV381025S0 Installing front oil seal
( — ) a: 77 mm (3.03 in) dia.
Oil seal fitting tool b: 55 mm (2.17 in) dia. BR
1 ST30720000 c: 71 mm (2.80 in) dia.
(J25405) d: 65 mm (2.56 in) dia.
Drift bar
2 KV38102510
ST
( — )
Drift NT525
RS
Differential shim selec-
tor BT
HA
SC
NT134
EL
IDX
PD-65
Tool number
Tool name

Side bearing discs
(2 Req’d)
NT135
KV381052S0 Checking differential torque on limited slip differen-

( — ) tial
Rear axle shaft dummy
1 KV38105210
( — )
Torque wrench side
2 KV38105220
NT142
( — )
Vise side

(J25273) a: 85 mm (3.35 in) dia.
seal drift
NT115

PD-66
On-vehicle Service
On-vehicle Service
FRONT OIL SEAL REPLACEMENT
1.
=NEPD0030
GI
PD-9.
2. Loosen drive pinion nut. MA
Tool number: KV38108300 (J-44195)
EM
SPD479A LC
4. Remove ABS sensor and sensor rotor (2WD models).
EC
FE
CL
SPD737
MT
AT
TF
AX
SPD738

Press front oil seal into carrier. SU
Tool number:
KV38100500 (J25273) BR
7. Install ABS sensor and sensor rotor (2WD models).
8. Install companion flange and drive pinion nut.
9. Install rear propeller shaft. ST
RS
SPD739
BT
HA
SC
EL
IDX
PD-67
Components
Components NEPD0031
WPD010
PD-68

REMOVAL
쐌 Remove rear propeller shaft. Refer to “Removal and
NEPD0032S01
GI
Plug front end of transfer. MA
쐌 Remove axle shaft.
Refer to AX-30, “REMOVAL”.
쐌 Remove rear final drive mounting bolts. EM
CAUTION:
Be careful not to damage spline, sleeve yoke and front oil seal
when removing propeller shaft. LC
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 EC
assembly area. Failure to do so may result in the sensor wires
being damaged and the sensor becoming inoperative.
FE
CL
MT
쐌 Fill final drive with recommended gear oil. AT
TF
AX
SPD123
쐌 Pay attention to the direction of gasket.

SU
BR
ST
RS
SPD767
BT
Before disassembling final drive, perform the following inspection. HA
쐌 Total preload
a) Turn drive pinion in both directions several times to seat bear-
ing rollers correctly. SC
Total preload:
EL
SPD149 1.7 - 2.5 N·m (17 - 25 kg-cm, 15 - 22 in-lb)
IDX
PD-69
쐌 Ring gear to drive pinion backlash
points.
0.13 - 0.18 mm (0.0051 - 0.0071 in)
SPD246

Runout limit:
0.08 mm (0.0031 in)
SPD247
쐌 Tooth contact
쐌 Side gear to pinion mate gear backlash
Measure clearance between side gear thrust washer and dif-
ferential case with a feeler gauge.
ential case:
0.10 - 0.20 mm (0.0039 - 0.0079 in)
SPD004

1. Mount final drive assembly on Tool.
Tool number:
ST06340000 (J24310, J34310)
SPD683
punch to ensure that it is replaced in proper position during
reassembly.
be put back in their original places.
SPD249
PD-70
3. Remove side lock fingers and side bearing caps.
GI
MA
EM
SPD250 LC
4. Remove side bearing adjuster with Tool.
Tool number: ST32580000 (J34312)
EC
FE
CL
SPD684
MT
5. Remove differential case assembly with a pry bar.
AT
TF
AX
SPD685
Keep the side bearing outer races together with their respec-
tive inner cones — do not mix them up. SU
BR
ST
RS
SPD011
6. Remove drive pinion nut with Tool. BT

Tool number: KV38108300 (J-44195)
8. Remove ABS sensor and sensor rotor (2WD models). HA
SC
EL
SPD480A
IDX
PD-71
9. Take out drive pinion together with pinion rear bearing inner
cone, drive pinion bearing spacer and pinion bearing adjusting
shim.
SPD687
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

To prevent damage to bearing, engage puller jaws in
groove.
Tool number:
A ST33051001 (J22888-20)
B ST33061000 (J8107-2)
SPD207A
Be careful not to confuse the left-hand and right-hand parts.

Keep bearing and bearing race for each side together.
SPD022
PD-72
3. Tap ring gear off differential case with a soft hammer.
GI
MA
EM
SPD024 LC
4. Drive out pinion mate shaft lock pin, with punch from ring gear
side.
Lock pin is caulked at pinhole mouth on differential case.
EC
FE
CL
SPD025
MT
Inspection NEPD0034
RING GEAR AND DRIVE PINION AT
NEPD0034S01
Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive pinion TF
as a set (hypoid gear set).
AX

Check mating surfaces of differential case, side gears, pinion mate
SU
gears, pinion mate shaft, and thrust washers.
BR
ST
RS
SPD530-A
BEARING NEPD0034S03
BT
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged, HA
replace outer race and inner cone as a set.
SC
EL
SPD715
IDX
PD-73
Limited Slip Differential
Limited Slip Differential

PREPARATION FOR DISASSEMBLY NEPD0035
CAUTION:
Do not run engine when only one wheel (rear) is off the
ground.
Checking Differential Torque NEPD0035S01

Measure differential torque with Tool.
If it is not within the specifications, inspect components of limited
slip differential.
Differential torque:
187 - 245N·m (19 - 25 kg-m, 138 - 180 ft-lb)
Tool number: A KV38105210 ( — )
Tool number: B KV38105220 ( — )
SPD415
DISASSEMBLY NEPD0036
APD027
CAUTION:
Do not run engine when one wheel (rear) is off the ground.
PD-74
Limited Slip Differential (Cont’d)
1. Remove side bearing inner cone with Tool.
3. Tap ring gear off gear case with a soft hammer. GI
MA
EM
SPD275 LC
4. Remove couple bolts on differential cases A and B with a
press.
Tool number: ST33081000 ( — )
EC
5. Separate differential case A and B.
Draw out component parts (discs and plates, etc). FE
Put marks on gears and pressure rings so that they can be
reinstalled in their original positions from which they were
removed. CL
SPD363A
MT
INSPECTION NEPD0037
Contact Surfaces NEPD0037S01
AT
1. Clean the disassembled parts in suitable solvent and blow dry
with compressed air.
2. If following surfaces are found with burrs or scratches, smooth
TF
with oil stone.
1 Differential case B
2 Differential case A
3 Side gear
4 Pinion mate gear AX
5 Pinion mate shaft
6 Friction plate guide
SU
BR
ST
RS
SPD359A
Disc and Plate NEPD0037S02

BT
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. HA
SC
EL
IDX
PD-75
3. Check friction discs or plates for warpage.
Allowable warpage:
0.08 mm (0.0031 in)
If it exceeds limits, replace with a new plate to eliminate pos-
sibility of clutch slippage or sticking.
SPD279
4. Measure frictional surfaces and projected portions of friction

disc, friction plate, spring plate, and determine each part’s dif-
ferences to see if the specified wear limit has been exceeded.
If any part has worn beyond the wear limit, and deformed or
fatigued, replace it with a new one that is the same thickness as
the projected portion.
Wear limit:
0.1 mm (0.004 in) or less
A − B = Wear limit mm (in)
쐌 Measuring points:
A: Projected portion
B: Frictional surface
SPD381A
ADJUSTMENT NEPD0038
Friction Disc and Friction Plate End Play NEPD0038S01
End play of friction disc and friction plate can be calculated by using
following equation and should be adjusted within following range.
Adjustment can be made by selecting friction disc having two dif-
ferent thicknesses.
End play E:
0.05 - 0.15 mm (0.0020 - 0.0059 in)
E = A − (B + C)
A: Length of differential case contact surface to differential case
SPD383A
inner bottom.
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 of side
gear.
SPD417
PD-76
1. Measure values of “A”.
Standard length A:
49.50 - 49.55 mm (1.9488 - 1.9508 in) GI
MA
EM
SPD417 LC
2. Measure thickness of each disc and plate.
Total thickness “B”:
EC
19.24 - 20.26 mm (0.7575 - 0.7976 in)
No. of discs and plates (One side):
Friction disc 5 FE
Friction plate 6
Spring plate 2
CL
SPD420
MT
3. Measure values of “C”.
a. Attach a dial indicator to the base plate. AT
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 TF
the master gauge.
AX
SPD418
c. Install pinion mate gears, side gears and pinion mate shaft in
differential case B. SU
d. Set dial indicator tip on the side gear, and read the indication.
Example:
E = A − D = A − (B + C) = 0.05 to 0.15 mm
BR
A = 49.52 mm
B = 19.45 mm ST
C = 29.7 mm
D=B+C
49.15 (D) = 19.45 (B) + 29.7 (C) RS
E=A−D
SPD419
0.37 (E) = 49.52 (A) − 49.15 (D)
From the above equation, end play of 0.37 mm exceeds the speci- BT
fied range of 0.05 to 0.15 mm.
Select suitable discs and plates to adjust correctly.
HA
SC
EL
IDX
PD-77
ASSEMBLY NEPD0039
Prior to assembling discs and plates, properly lubricate them by
dipping them in limited slip differential oil. Refer to MA-13, “RECOM-
MENDED FLUIDS AND LUBRICANTS”.
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
2. Install spring plate.
SPD384A
3. Install friction plate guides.

Correctly align the raised portions of friction plates, and apply
grease to inner surfaces of friction plate guides to prevent
them from falling.
SPD385A
4. Install differential case B over side gear, discs, plates and fric-
tion plate guide assembly.
쐌 Install differential case B while supporting friction plate
guides with your middle finger inserted through oil hole in
differential case.
쐌 Be careful not to detach spring disc from the hexagonal
part of the side gear.
SPD386A
5. Install pinion mate gears and pinion mate thrust washers on

pinion mate shaft, then install pinion mate shaft in differential
case B.
SPD426
PD-78
6. Install side gear to pinion mate gears.
7. Install each disc and plate.
Use same procedures as outlined in steps 1 through 4 above. GI
MA
EM
SPD387A LC
8. Install differential case A.
Position differential cases A and B by correctly aligning marks EC
stamped on cases.
FE
CL
SPD388A
MT
9. Tighten differential case couple bolts.
10. Place ring gear on differential case and tighten ring gear bolts. AT
Then bend up lock straps to lock the bolts in place.
11. Install side bearing inner cone.
TF
12. Check differential torque.
AX
SPD364A
Adjustment NEPD0040 SU
For quiet and reliable final drive operation, the following five adjust-
ments must be made correctly:
1. Side bearing preload. Refer to “Total Preload Adjustment”, BR
PD-89.
2. Pinion gear height. Refer to “PINION GEAR HEIGHT”, PD-80.
3. Pinion bearing preload. Refer to “Drive Pinion Preload ST
4. Ring gear-to-pinion backlash. Refer to “Total Preload RS
CONTACT”, PD-83. BT
HA
SC
EL
IDX
PD-79
PINION GEAR HEIGHT NEPD0040S01
lubricated.
2. Assemble the pinion gear bearings into the pinion pre-load
shim selector tool, J34309.
SPD196A
쐌 Rear Pinion Bearing — the rear pinion bearing pilot,

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.
쐌 Front Pinion Bearing — make sure the J34309-3, front pin-
ion bearing seat is secured tightly against the J34309-2 gauge
secure the bearing in its proper position.
SPD197A
3. Place the pinion preload shim selector tool gauge screw

assembly, J34309-1, with the pinion rear bearing inner cone
installed, into the final drive housing.
SPD216A
4. Install the J34309-2 gauge anvil with the front pinion bearing
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
to set bearing preload.
SPD217A

anvil using torque wrench J25765-A.
0.4 - 0.9 N·m (4 - 9 kg-cm, 3.5 - 7.8 in-lb)
SPD234A
PD-80
7. Place the J34309-12 “H233B” pinion height adapter onto the
gauge plate and tighten it by hand.
CAUTION: GI
MA
EM
SPD208A LC
PINION HEIGHT ADJUSTING WASHER SELECTION
8. Position the J25269-18 side bearing discs and the arbor into
the side bearing bores.
EC
FE
CL
SPD286A
MT
9. Install the bearing caps and torque the bolts.
Specification: AT
93 - 103 N·m (9.5 - 10.5 kg-m, 69 - 76 ft-lb)
TF
AX
SPD237A
10. Select the correct standard pinion height adjusting washer

thickness using a standard gauge of 2.5, 3.0, or 3.5 mm SU
(0.098, 0.118, or 0.138 in) and the J34309-101 feeler gauge.
Measure the distance between the J34309-12 “H233B” pinion
height adapter and the arbor. BR
11. Write down the exact total measurement.
ST
RS
SPD204A
12. Correct the pinion height washer size by referring to the “pin- BT
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 HA
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- SC
tion. Use the following chart to determine the correct pinion
height washer. Refer to “Drive Pinion Height Adjustment”,
PD-89. EL
SPD542
IDX
PD-81
Add or Remove from the Selected

Pinion Head Height Number Standard Pinion Height Washer
Thickness Measurement
−6 Add 0.06 mm (0.0024 in)
−5 Add 0.05 mm (0.0020 in)
−4 Add 0.04 mm (0.0016 in)
−3 Add 0.03 mm (0.0012 in)
−2 Add 0.02 mm (0.0008 in)
−1 Add 0.01 mm (0.0004 in)
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)
13. Select the correct pinion height washer.

Drive pinion height adjustment:
14. Remove the J34309 pinion preload shim selector tool from the
final drive housing and disassemble to retrieve the pinion
bearings.
SPD220A
PD-82

Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion. GI
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 MA
life can be assured.
EM
LC
EC
FE
CL
SPD005
MT
3. Hold companion flange steady by hand and rotate the ring gear
in both directions. AT
TF
AX
SPD695
SU
BR
ST
RS
BT
HA
SC
SPD007-B
EL
IDX
PD-83
Assembly
Assembly NEPD0041
1. Install side gears, pinion mate gears and thrust washers into
differential case.
The clearance can be adjusted with side gear thrust washer.
SPD552
2. Fit pinion mate shaft to differential case so that it meets lock

pinholes.
3. Adjust backlash between side gear and pinion mate gear by
selecting side gear thrust washer.
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and differ-
ential case:
0.10 – 0.20 mm (0.0039 – 0.0079 in)
SPD258
4. Install pinion mate shaft lock pin with a punch.

Make sure lock pin is flush with case.
SPD030
check to see that they turn properly.
6. Install differential case assembly on ring gear.
SPD322
7. Press-fit side bearing inner cones on differential case with Tool.

Tool number:
A ST33190000 (J25523)
B ST33081000 ( — )
PD244
PD-84
Assembly (Cont’d)
Tool number: GI
A ST30611000 (J25742-1)
B ST30621000 (J25742-5) MA
C ST30613000 (J25742-3)
EM
LC
EC
FE
CL
SPD580
MT
2. Select drive pinion height adjusting washer. Refer to “Drive
Pinion Height Adjustment”, PD-89. AT
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: TF
ST30901000 (J26010-01)
AX
SPD377
4. Place pinion front bearing inner cone in gear carrier.

SU
BR
ST
RS
SPD581
5. Apply multi-purpose grease to cavity at sealing lips of oil seal. BT

Tool number:
A ST30720000 (J25405) HA
B KV38102510 ( — )
SC
EL
SPD291A
IDX
PD-85
Assembly (Cont’d)
6. Install drive pinion bearing spacer, pinion bearing adjusting
shim and drive pinion in gear carrier.
SPD935-A
7. Install ABS sensor and sensor rotor (2WD models), then com-
panion flange onto drive pinion. Tap the companion flange with
a soft hammer until fully seated.
SPD697
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: KV38108300 (J-44195)
SPD481A
9. Turn drive pinion in both directions several times, and measure

pinion bearing preload.
Pinion bearing preload (With front oil seal):
1.4 - 1.7 N·m (14 - 17 kg-cm, 12 - 15 in-lb)
Pinion bearing preload (Without front oil seal):
1.2 - 1.5 N·m (12 - 15 kg-cm, 10 - 13 in-lb)
If preload is out of specification, adjust the thickness of spacer and
shim combination by replacing shim and spacer with thinner one.
쐌 Start from the combination of thickest spacer and shim.
SPD149
쐌 Combine each spacer and shim thickness one by one until the
correct specification are achieved.
Drive pinion bearing preload adjusting spacer and
shim:
Refer to “Drive Pinion Preload Adjustment”, PD-90.
10. Install differential case assembly with side bearing outer races
into gear carrier.
11. Position side bearing adjusters on gear carrier with threads
properly engaged; screw in adjusters lightly at this stage of
assembly.
Tool number: ST32580000 (J34312)
SPD684
PD-86
Assembly (Cont’d)
12. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.
쐌 Do not tighten at this point. This allows further tightening of GI
side bearing adjusters.
MA
EM
SPD265 LC
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 EC
them alternately so that proper ring gear backlash and total
preload can be obtained.
FE
0.13 - 0.18 mm (0.0051 - 0.0071 in)
CL
SPD246
MT
쐌 When checking preload, turn drive pinion in both direc-
tions several times to set bearing rollers. AT
Total preload:
1.7 - 2.5 N·m (17 - 25 kg-cm, 15 - 22 in-lb) TF
AX
SPD149
14. Tighten side bearing cap bolts.

15. Install side lock finger in place to prevent rotation during opera-
SU
tion.
BR
ST
RS
SPD698
16. Check runout of ring gear with a dial indicator. BT

may have resulted from foreign matter caught between the ring HA
gear and the differential case.
is within a specified range, the hypoid gear set or differential SC
case should be replaced.
17. Check tooth contact. Refer to “TOOTH CONTACT”, PD-83. EL
SPD247
IDX
PD-87

H233B
General Specifications =NEPD0042
2WD Model NEPD0042S02
Engine VG33E VG33ER
Vehicle grade XE, SE SC
Standard Optional* Standard Optional*
Rear final drive H233B
2-pinion LSD 2-pinion LSD
Gear ratio 4.636 4.363
Number of teeth (Ring gear/drive pinion) 51/11 48/11
Oil capacity (Approx.)

2.8 (5-7/8, 4-7/8)
(US pt, lmp pt)
*: Standard on Canada models.

4WD Model NEPD0042S03
Engine VG33E VG33ER
Vehicle grade XE SE SC
Standard Optional Standard Optional* Standard Optional*
Rear final drive H233B
2-pinion LSD 2-pinion LSD 2-pinion LSD
Gear ratio 4.636 4.900 4.363
Number of teeth (Ring gear/drive pinion) 51/11 49/10 48/11
Oil capacity (Approx.)

2.8 (5-7/8, 4-7/8)
(US pt, lmp pt)
*: Standard on Canada models.
Ring Gear Runout NEPD0043
Side Gear Adjustment NEPD0044
0.10 - 0.20 (0.0039 - 0.0079)
(in)

Available side
gear thrust 1.75 (0.0689) 38424-T5000
washers 1.80 (0.0709) 38424-T5001
1.85 (0.0728) 38424-T5002
PD-88
Differential Torque Adjustment (LSD Models) NEPD0045
Differential torque N·m (kg-m, ft-lb) 187 - 245 (19 - 25, 138 - 180)
GI
Friction disc 5
Number of discs and plates (One side) Friction plate 6

MA
Spring plate 2
Wear limit of plate and disc mm (in) 0.1 (0.004) EM

Allowable warpage of friction disc and plate mm (in) 0.08 (0.0031)
Plate name Thickness mm (in) Part number* LC

1.48 - 1.52 (0.0583 - 0.0598) 38433-C6002 (Standard type)
Friction disc 1.38 - 1.42 (0.0543 - 0.0559) 38433-C6004 (Adjusting type)
Available discs
and plates
1.58 - 1.62 (0.0622 - 0.0638) 38433-C6003 (Adjusting type) EC
Friction plate 1.48 - 1.52 (0.0583 - 0.0598) 38432-C6001
Spring plate 1.48 - 1.52 (0.0583 - 0.0598) 38435-S9200 FE

Total Preload Adjustment NEPD0046

CL
Ring gear to pinion backlash mm (in) 0.13 - 0.18 (0.0051 - 0.0071)

MT
Side bearing adjusting method Side adjuster
AT
Drive Pinion Height Adjustment NEPD0047
Thickness mm (in) Part number* TF

2.58 (0.1016) 38151-01J00
2.61 (0.1028) 38151-01J01
2.64 (0.1039) 38151-01J02
2.67 (0.1051) 38151-01J03
2.70 (0.1063) 38151-01J04
2.73 (0.1075) 38151-01J05
2.76 (0.1087) 38151-01J06 AX
2.79 (0.1098) 38151-01J07
2.82 (0.1110) 38151-01J08
2.85 (0.1122) 38151-01J09 SU
2.88 (0.1134) 38151-01J10
2.91 (0.1146) 38151-01J11
2.94 (0.1157) 38151-01J12
2.97 (0.1169) 38151-01J13 BR
3.00 (0.1181) 38151-01J14
3.03 (0.1193) 38151-01J15
Available pin- 3.06 (0.1205)
3.09 (0.1217)
38151-01J16
38151-01J17
ST
ion height
adjust washers 3.12 (0.1228) 38151-01J18
3.15 (0.1240) 38151-01J19
3.18 (0.1252) 38151-01J60 RS
3.21 (0.1264) 38151-01J61
3.24 (0.1276) 38151-01J62
3.27 (0.1287) 38151-01J63
3.30 (0.1299) 38151-01J64
BT
3.33 (0.1311) 38151-01J65
3.36 (0.1323) 38151-01J66
3.39 (0.1335) 38151-01J67 HA
3.42 (0.1346) 38151-01J68
3.45 (0.1358) 38151-01J69
3.48 (0.1370) 38151-01J70
3.51 (0.1382) 38151-01J71
SC
3.54 (0.1394) 38151-01J72
3.57 (0.1406) 38151-01J73
3.60 (0.1417) 38151-01J74 EL
3.63 (0.1429) 38151-01J75
3.66 (0.1441) 38151-01J76
IDX
PD-89
Drive Pinion Preload Adjustment NEPD0048
Drive pinion bearing preload adjusting method Adjusting shim and spacer
Drive pinion preload without front oil seal N·m (kg-cm, in-lb) 1.4 - 1.7 (14 - 17, 12 - 15)
2.31 (0.0909) 38125-82100

2.33 (0.0917) 38126-82100
2.35 (0.0925) 38127-82100
2.37 (0.0933) 38128-82100
2.39 (0.0941) 38129-82100
Available front
2.41 (0.0949) 38130-82100
drive pinion
2.43 (0.0957) 38131-82100
bearing adjust-
2.45 (0.0965) 38132-82100
ing shims
2.47 (0.0972) 38133-82100
2.49 (0.0980) 38134-82100
2.51 (0.0988) 38135-82100
2.53 (0.0996) 38136-82100
2.55 (0.1004) 38137-82100
2.57 (0.1012) 38138-82100
2.59 (0.1020) 38139-82100

Available drive
4.50 (0.1772) 38165-76000
pinion bearing
4.75 (0.1870) 38166-76000
adjusting spac-
5.00 (0.1969) 38167-76000
ers
5.25 (0.2067) 38166-01J00
5.50 (0.2165) 38166-01J10
PD-90

Propeller Shaft & Differential Carrier

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Propeller Shaft & Differential Carrier

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PROPELLER SHAFT &

PROPELLER SHAFT ......................................................3 DIFFERENTIAL CASE ..............................................23

KV38108300 Removing and installing propeller shaft lock nut,

Excessive joint angle —

Tooth surfaces worn PD-24, 49, 73

Incorrect backlash PD-20, 45, 69

REAR PROPELLER SHAFT NEPD0002S02

A/T 226 485 —

A/T 241 491 —

2S1310 (4WD) All 237 623.5 237

3. If runout exceeds specifications, disconnect propeller shaft at

Removal and Installation NEPD0005

쐌 If the play exceeds specifications, replace propeller shaft

3. Remove locking nut with Tool.

5. Remove center bearing with Tool and press.

2. Remove snap ring.

쐌 Stake the nut. Always use a new one.

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

Service Data and Specifications (SDS)

Applied model Standard wheelbase Long wheelbase

Coupling method with transmission Sleeve type

2WD VG33E and VG33ER Models NEPD0009S03

Transmission M/T A/T M/T A/T MT

Solid type (disassembly type with-

Shaft outer diameter mm (in)

Propeller shaft model 2F1310 2S1310 2F1310 2S1310

Distance between yokes mm (in) 71 (2.80) 80 (3.15) 71 (2.80) 80 (3.15)

Journal axial play 0.02 (0.0008) or less

ST3127S000 Measuring pinion bearing preload and total preload

KV38100800 Mounting final drive

KV38108300 Removing and installing propeller shaft lock nut,

ST3090S000 Removing and installing drive pinion rear inner

ST3306S001 Removing and installing differential side bearing

KV38100300 Installing side bearing inner cone

ST30621000 Installing pinion rear bearing outer race

ST30613000 Installing pinion front bearing outer race MT

(J34309) Adjusting bearing pre-load and gear height

(J8129) Measuring carrier turning torque

Noise, Vibration and Harshness (NVH)

3. Remove companion flange.

4. Remove front oil seal.

Removal and Installation NEPD0017

쐌 Ring gear runout

쐌 Side gear to pinion mate gear backlash

FINAL DRIVE HOUSING NEPD0018S02

5. Remove side bearing caps.

6. Remove differential case assembly with a pry bar. BT

7. Loosen drive pinion nut.

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

DIFFERENTIAL SIDE SHAFT NEPD0018S04

3. Remove grease seal and oil seal.

SIDE BEARING PRELOAD NEPD0020S01

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

5. Install the side bearing caps in their correct locations and

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

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

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

7. Place the J34309-1 “R200A” pinion height adapter onto the

PINION BEARING PRELOAD WASHER SELECTION