PROPELLER SHAFT & GI

DIFFERENTIAL CARRIER
MA

SECTION PD EM

LC

EC

FE

CONTENTS CL
PREPARATION................................................................2 Bearing.......................................................................21
Special Service Tools ..................................................2 LIMITED SLIP DIFFERENTIAL.....................................22 MT
Commercial Service Tool.............................................4 Preparation for Disassembly .....................................23
NOISE, VIBRATION AND HARSHNESS (NVH) Disassembly...............................................................23
AT
TROUBLESHOOTING .....................................................5 Inspection...................................................................24
NVH Troubleshooting Chart.........................................5 Adjustment .................................................................25
PROPELLER SHAFT ......................................................6 Assembly ...................................................................26 TF
Front Propeller Shaft ...................................................6 ADJUSTMENT ...............................................................30
Rear Propeller Shaft ....................................................6 Drive Pinion Height....................................................30
On-vehicle Service.......................................................8 Tooth Contact.............................................................32
Removal and Installation .............................................8 ASSEMBLY....................................................................34
Inspection.....................................................................8 Differential Case - 4-pinion type - .............................34
Disassembly.................................................................9 Differential Case - 2-pinion type - .............................35
FA
Assembly ...................................................................10 Differential Carrier......................................................36
ON-VEHICLE SERVICE (Final Drive) ..........................11 DIFFERENTIAL LOCK ..................................................40 RA
Front Oil Seal Replacement ......................................11 Actuator and Fork ......................................................40
REMOVAL AND INSTALLATION ..................................12 Disassembly...............................................................41
Removal.....................................................................12 Inspection...................................................................42 BR
Installation..................................................................12 Assembly ...................................................................43
FRONT FINAL DRIVE ...................................................13 System Description....................................................46
REAR FINAL DRIVE .....................................................14 Component Parts Location ........................................47
ST
DISASSEMBLY..............................................................16 Wiring Diagram - DIFF/L -/LHD Models ....................48
Pre-inspection ............................................................16 Wiring Diagram - DIFF/L -/RHD Models....................50 RS
Differential Carrier......................................................17 Electrical Components Inspection .............................52
Differential Case ........................................................19 SERVICE DATA AND SPECIFICATIONS (SDS) ..........54
INSPECTION..................................................................21 Propeller Shaft ...........................................................54 BT
Ring Gear and Drive Pinion ......................................21 Final Drive..................................................................55
Differential Case Assembly........................................21
HA

EL

SE

IDX
 PREPARATION

Special Service Tools

*: For front differential carrier only

Tool number Unit application

Description
Tool name H260 H233B
ST0501S000 Mounting differential attach-
Engine stand ment
q
1 ST05011000
Engine stand
q
2 ST05012000 X X
Base

NT042

ST06340000 Mounting final drive

Differential attachment

— X

NT140

ST06350000 Mounting final drive

Differential attachment

X —

NT140

ST30611000 Installing pinion rear bearing

Drive pinion bearing outer outer race
race drift bar (Use with ST30621000 or
ST30613000) X X

NT090

ST30613000 Installing pinion front bearing

Drive pinion front bearing outer race
outer race drift (Use with ST30613000)
— X

a: 71.5 mm (2.815 in) dia.

NT073 b: 47.5 mm (1.870 in) dia.
ST30621000 Installing pinion rear bearing
Drive pinion rear bearing outer race
outer race drift (Use with ST30613000)
— X*

a: 79 mm (3.11 in) dia.

NT073 b: 59 mm (2.32 in) dia.
ST3090S000 Removing and installing drive
Drive pinion rear bearing pinion rear inner race
inner race puller set
q1 ST30031000
X X
Puller
q2 ST30911000 a: 79 mm (3.11 in) dia.
Base b: 45 mm (1.77 in) dia.
NT527 c: 35 mm (1.38 in) dia.

PD-2
 PREPARATION
Special Service Tools (Cont’d)
Unit application
GI
Tool number
Description
Tool name H260 H233B
ST3127S000 Measuring pinion bearing MA
Preload gauge preload and total preload
q
1 GG91030000
Torque wrench EM
X X
q
2 HT62900000
Socket adapter (1/2″)
q
3 HT62940000
LC
Socket adapter (3/8″) NT124

ST3124S000 Selecting pinion height EC

Drive pinion setting adjusting washer
gauge set
q1 ST31130000 FE
Height gauge
q2 ST31241000 X —
Dummy shaft CL

NT513
MT
ST3125S000 Selecting pinion height
Drive pinion setting adjusting washer AT
gauge set
q1 ST31251000
Drive pinion height — X TF
gauge
q2 ST31181001
Dummy shaft
NT524

KV38104700 Removing and installing pro-

Drive pinion flange peller shaft lock nut and drive FA
X —
wrench pinion lock nut

KV40104000
RA
NT113 — X

ST0237S000 Removing and installing side

BR
Differential side bearing bearing inner race
puller set
q1 ST33051001
X X ST
Puller
q2 ST02371000
Adapter a: 40 mm (1.57 in) dia.
NT072 b: 50 mm (1.97 in) dia.
RS
ST33081000 Installing side bearing inner
Adapter cone BT
X X
HA
a: 43 mm (1.69 in) dia.
NT431 b: 33.5 mm (1.319 in) dia.
ST33190000 Installing side bearing inner EL
Differential side bearing cone
drift
— X SE
a: 52 mm (2.05 in) dia.
b: 45.5 mm (1.791 in) dia.
NT085 c: 34 mm (1.34 in) dia.
IDX

PD-3
 PREPARATION
Special Service Tools (Cont’d)
Tool number Unit application
Description
Tool name H260 H233B
KV31100300 Removing pinion mate shaft
Fork rod pin punch lock pin
— X

NT410 a: 4.5 mm (0.177 in) dia.

KV381025S0 Installing front oil seal
Oil seal fitting tool
q
1 ST30720000
Drift bar
X X
q
2 KV38102510 a: 77 mm (3.03 in) dia.
Drift b: 55 mm (2.17 in) dia.
c: 71 mm (2.80 in) dia.
NT525 d: 65 mm (2.56 in) dia.
ST32580000 Adjusting side bearing pre-
Differential side bearing load and backlash (ring gear-
adjusting nut wrench drive pinion)

— X

NT141

ST32530000 Removing and installing side

Differential side bearing bearing adjuster
adjusting nut wrench

X —

NT530

KV38106400 Checking differential torque

Rear axle shaft dummy on limited slip differential
(Use 2 pieces per unit) X —

KV38106900
X —
NT516

Commercial Service Tool

Unit application
Tool name Description
H260 H233B
Drift Installing side bearing

X —
a: 64 mm (2.52 in) dia.
b: 56 mm (2.20 in) dia.
NT117 c: 160 mm (6.30 in)

PD-4
 X: Applicable
Reference page

PRO-

Symptom SHAFT

ENTIAL
Possible cause and

PELLER

DIFFER-
SUSPECTED PARTS

Noise
Noise
Shake
Vibration
X
X
Uneven rotation torque —

X
X
X
Excessive joint angle —

X
X
Rotation imbalance PD-8

X
X
Excessive runout PD-8

X
Rough gear tooth PD-21

X
Improper gear contact PD-32

PD-5
Tooth surfaces worn PD-21

X
Incorrect backlash PD-16

X
Companion flange excessive runout —

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.
NVH Troubleshooting Chart

X
X
X
X

AXLE AND SUSPENSION NVH in FA, RA section

X
X
X
X

TIRES NVH in FA section

X
X
X

ROAD WHEEL NVH in FA section

X
X
X
X

DRIVE SHAFT NVH in RA section

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

X
X
X

BRAKES NVH in BR section

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

STEERING NVH in ST section

GI

TF
AT

EL
FE

ST
FA

SE
BT
CL
LC

RS
EC

RA

HA
BR
MT
EM
MA

IDX
PROPELLER SHAFT

Front Propeller Shaft

SPD434A

Rear Propeller Shaft

SPD435A

PD-6
PROPELLER SHAFT
Rear Propeller Shaft (Cont’d)
GI

MA

EM

LC

EC

FE

CL

MT

AT

TF
SPD457A

FA

RA

BR

ST

RS

BT

HA

EL

SE
SPD458A

IDX

PD-7
 PROPELLER SHAFT

On-vehicle Service
PROPELLER SHAFT VIBRATION
If vibration is present at high speed, inspect propeller shaft runout
first.
1. Raise front and rear wheels.
2. Measure propeller shaft runout at several points by rotating
final drive companion flange with hands.
Runout limit: 0.6 mm (0.024 in)

SPD728

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 tests.

APPEARANCE CHECKING
I Inspect propeller shaft tube surface for dents or cracks. If
damaged, replace propeller shaft assembly.
SPD102

Removal and Installation

I Put matchmarks on flanges and separate propeller shaft from
final drive.

SPD103

CAUTION:
When installing the propeller shaft, make sure it is facing the
correct direction. Each model is different.

Inspection
I Inspect propeller shaft runout. If runout exceeds specifications,
replace propeller shaft assembly.
Runout limit: 0.6 mm (0.024 in)

SPD106

I Inspect journal axial play.

If the play exceeds specifications, replace propeller shaft
assembly.
Journal axial play:
0.02 mm (0.0008 in) or less

SPD874

PD-8
 PROPELLER SHAFT
Inspection (Cont’d)
I Check flange yoke and sleeve yoke for damage or wear. GI
Replace if necessary.

MA

EM

LC
SPD189

Disassembly EC
JOURNAL
FE
1. Put matchmarks on shaft and flange or yoke.

CL

MT
SPD128
AT
2. Remove snap ring.

TF

FA

SPD731
RA
3. Remove pushed out journal bearing by lightly tapping yoke with
a hammer, taking care not to damage journal and yoke hole.
BR

ST

RS

SPD732 BT
4. Remove bearing at opposite side in above operation.
Put marks on disassembled parts so that they can be rein- HA
stalled in their original positions from which they were
removed.
EL

SE

SPD131
IDX

PD-9
 PROPELLER SHAFT

Assembly
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 direc-
tion of journal, and install them. (Refer to SDS.)
Select snap rings with a difference in thickness at both sides
within 0.06 mm (0.0024 in).

SPD134

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-10
ON-VEHICLE SERVICE (Final Drive)

Front Oil Seal Replacement GI

1. Remove propeller shaft.
2. Loosen drive pinion nut. MA
Tool number:
H233B KV40104000
H260 KV38104700 EM

LC
PD237

3. Remove companion flange. EC

FE

CL

MT
SPD737
AT
4. Remove front oil seal.

TF

FA

SPD738
RA
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. BR
7. Install propeller shaft.
Tool number: KV381025S0
ST

RS

SPD739 BT

HA

EL

SE

IDX

PD-11
REMOVAL AND INSTALLATION

Removal
I Remove propeller shaft.
I Remove drive shaft. Refer to FA section (“FRONT AXLE —
Knuckle Flange”).
I Remove axle shaft.
Refer to RA section (“REAR AXLE”).
I Remove front and rear final drive mounting bolts.
CAUTION:
I Be careful not to damage spline, sleeve yoke and front oil
seal when removing propeller shaft.
SPD103 I 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
I Fill final drive with recommended gear oil.

SPD123

I Pay attention to the direction of gasket (H233B only).

SPD767

PD-12
FRONT FINAL DRIVE

GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX
SPD436A

PD-13
REAR FINAL DRIVE

SPD437A

PD-14
REAR FINAL DRIVE

GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX
SPD438A

PD-15
 DISASSEMBLY

Pre-inspection
Before disassembling final drive, perform the following inspection.
I Total preload
1) Turn drive pinion in both directions several times to set bearing
rollers.
2) Check total preload with Tool.
Tool number: ST3127S000
Total preload (with front oil seal):
Drive pinion bearing
New parts
SPD149 1.7 - 2.5 N⋅m (17 - 25 kg-cm, 15 - 22 in-lb)
Used parts
1.5 - 1.7 N⋅m (15 - 17 kg-cm, 13 - 15 in-lb)

I Ring gear to drive pinion backlash

Check ring gear-to-drive pinion backlash with a dial indicator at
several points.
Ring gear-to-drive pinion backlash:
H233B
0.15 - 0.20 mm (0.0059 - 0.0079 in)
H260
0.18 - 0.23 mm (0.0071 - 0.0091 in)

SPD246

I Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit:
0.08 mm (0.0031 in)
I Tooth contact
Check tooth contact. Refer to ADJUSTMENT (PD-30).

SPD247

I 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 differ-
ential case:
0.15 - 0.20 mm (0.0059 - 0.0079 in)

SPD004

PD-16
 DISASSEMBLY

Differential Carrier GI
1. Mount differential carrier on Tools.
Tool number: MA
q
A ST0501S000
q
B H233B ST06340000
H260 ST06350000 EM

LC
SPD139

2. Put matchmarks on one side of side bearing cap with paint or EC

punch to ensure that it is replaced in proper position during
reassembly.
Bearing caps are line-bored during manufacture and should FE
be put back in their original places.
CL

MT
SPD249
AT
3. Remove side lock fingers and side bearing caps.

TF

FA

SPD250
RA
4. Remove side bearing adjuster with Tool.
Tool number:
H233B ST32580000 BR
H260 ST32530000
ST

RS

SPD684 BT
5. Remove differential case assembly with a pry bar.
HA

EL

SE

SPD685
IDX

PD-17
 DISASSEMBLY
Differential Carrier (Cont’d)
Be careful to keep the side bearing outer races together with
their respective inner cones — do not mix them up.

SPD011

6. Loosen drive pinion nut with Tool.

Tool number: KV38104700

SPD012

7. Remove companion flange with puller.

SPD686

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

SPD687

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

SPD563

PD-18
 DISASSEMBLY
Differential Carrier (Cont’d)
11. Remove pinion rear bearing inner cone and drive pinion height GI
adjusting washer with press and Tool.
Tool number: ST30031000
MA

EM

LC
SPD018

Differential Case EC
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove. FE
Tool number:
H233B q A ST33051001
qB ST02371000 CL
H260 qA ST33051001
qB ST02371000
MT
SPD207A
AT
Be careful not to confuse left and right hand parts.
Keep bearing and bearing race for each side together.
TF

FA

SPD022
RA
2. Loosen ring gear bolts in a criss-cross pattern.
3. Tap ring gear off differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding. BR

ST

RS

SPD024 BT
4. Drive out pinion mate shaft lock pin, with punch from ring gear
side (2-pinion type differential case). HA
Lock pin is calked at pin hole mouth on differential case.

EL

SE

SPD025
IDX

PD-19
 DISASSEMBLY
Differential Case (Cont’d)
5. Separate differential case LH and RH (4-pinion type differential
case).
Put matchmarks on both differential case LH and RH sides
prior to separating them.

SPD716

PD-20
 INSPECTION

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 as a set (hypoid MA
gear set).

EM

LC

Differential Case Assembly EC

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

CL

MT
SPD530
AT

TF

FA

RA

BR

ST

RS

SPD717 BT
Bearing
1. Thoroughly clean bearing. HA
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. EL

SE

SPD715
IDX

PD-21
LIMITED SLIP DIFFERENTIAL

SPD439A

SPD440A

CAUTION:
Do not run engine when one wheel (rear) is off the ground.
PD-22
LIMITED SLIP DIFFERENTIAL

Preparation for Disassembly GI

CHECKING DIFFERENTIAL TORQUE
Measure differential torque with Tool. MA
If it is not within the specifications, inspect components of limited
slip differential.
Differential torque: EM
H233B
108 - 137 N⋅m (11 - 14 kg-m, 80 - 101 ft-lb)
H260 LC
157 - 186 N⋅m (16 - 19 kg-m, 116 - 137 ft-lb)
SPD508
Tool number: KV38106400
Disassembly EC
1. Remove side bearing inner cone with Tool.
2. Loosen ring gear bolts in a criss-cross pattern. FE
3. Tap ring gear off gear case with a soft hammer.
Tap evenly all around to keep ring gear from binding.
CL

MT
SPD476
AT
4. Loosen screws on differential cases A and B using a press.
5. Separate differential cases A and B. Draw out component parts
(discs and plates, etc.). TF
Put marks on gears, discs and plates so that they can be rein-
stalled in their original positions from which they were
removed.

FA

SPD507
RA

BR

ST

RS

BT

HA

EL

SE

IDX

PD-23
 LIMITED SLIP DIFFERENTIAL

Inspection
CONTACT SURFACES
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
with oil stone.

SPD503

q
1 Differential case A q
4 Thrust washer q
7 Pinion mate gear
q
2 Differential case B q
5 Pinion mate shaft q
8 Side gear
q
3 Pressure ring q
6 Thrust block

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.

SPD478

3. To test if friction disc or plate is not distorted, place it on a sur-

face plate and rotate it by hand with indicating finger of dial
gauge resting against disc or plate surface.
Allowable warpage:
0.08 mm (0.0031 in)
If it exceeds limits, replace with a new plate to eliminate possi-
bility of clutch slippage or sticking.

SPD279

PD-24
LIMITED SLIP DIFFERENTIAL
Inspection (Cont’d)
4. Measure frictional surfaces and projected portions of friction GI
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 MA
fatigued, replace it with a new one that is the same thickness
as the projected portion.
Wear limit: EM
0.1 mm (0.004 in) or less

LC

EC

FE

CL

MT
SPD403
AT
Adjustment
FRICTION DISC AND FRICTION PLATE END PLAY TF
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) FA
E = A − (B + C)
A: Length of differential case contact surface to differen-
SPD761
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

BT
1. Measure values of “A”.
Standard length A: HA
49.50 - 49.55 mm (1.9488 - 1.9508 in)

EL

SE

SPD417
IDX

PD-25
LIMITED SLIP DIFFERENTIAL
Adjustment (Cont’d)
2. Measure thickness of each disc and plate.
Total thickness “B”:
19.24 - 20.26 mm (0.7575 - 0.7976 in)

SPD420

3. Measure values of “C”.

(1) Attach a dial indicator to the base plate.
(2) 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

(3) Install pinion mate gears, side gears and pinion mate shaft in
differential case B.
(4) 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
SPD419
+C .... 29.7 −D .... 49.15
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
Assemble differential case in the reverse order of disassembly,
observing the following.
1. As an aid to installation, apply sufficient amounts of recom-
mended limited slip differential gear oil (refer to MA section) to
the faces of pressure rings, discs and plates to be assembled
together.

SPD479

PD-26
LIMITED SLIP DIFFERENTIAL
Assembly (Cont’d)
2. Place differential case B on a level surface, then install thrust GI
washer.

MA

EM

LC
SPD406

3. Install spring plates, friction plates and friction discs. EC

Pay particular attention to the direction of clutch plates and
their assembly sequence.
FE

CL

MT
SPD504
AT
4. Install pressure ring.

TF

FA

SPD481
RA
5. Install side gear by inserting projected portion of disc.
BR

ST

RS

SPD482 BT
6. Install pinion mate gears and shaft.
Always attach pinion mate shaft to “V” groove in pressure ring HA
with flat surfaces facing up and down.

EL

SE

SPD483
IDX

PD-27
LIMITED SLIP DIFFERENTIAL
Assembly (Cont’d)
7. Install thrust block.

SPD505

8. Install differential case A side components in the opposite way

of differential case B components.
9. Apply gear oil to differential case A, and attach thrust washer
to it.

SPD506

10. Install differential case A on differential case B. Align the match-

ing marks on the cases, then install screws while pushing dif-
ferential case down using a press.
Press force:
7,846 N (800 kg, 1,764 lb)

SPD507

11. After all parts have been assembled, check and adjust the fol-
lowing:

PD-28
LIMITED SLIP DIFFERENTIAL
Assembly (Cont’d)
DIFFERENTIAL TORQUE INSPECTION GI
a. Place side gear in a vise with Tool into the gear splines.
b. Turn side gear several times, then measure the differential
torque after side gear begins to rotate in order to determine MA
whether it is within the specified range. If it is not, adjust it by
selecting a friction disc. (Refer to SDS for adjustment parts.)
Differential torque: EM
H233B
108 - 137 N⋅m (11 - 14 kg-m, 80 - 101 ft-lb)
H260
LC
SPD508 157 - 186 N⋅m (16 - 19 kg-m, 116 - 137 ft-lb)
Tool number: KV38106400 EC

FE

CL

MT

AT
SIDE GEAR BACKLASH INSPECTION
Check backlash of side gear on both sides. Using a feeler gauge,
measure clearance between side gear and thrust washer. If it is not TF
within specifications, adjust it by selecting a thrust washer. (Refer
to SDS.)
Side gear backlash:
Differential case A side
0.05 - 0.20 mm (0.0020 - 0.0079 in)
Differential case B side FA
0.05 - 0.20 mm (0.0020 - 0.0079 in)
SPD411
RA
12. After checking and adjusting, tighten ring gear bolts in a criss-
cross fashion.
13. Bend up lock straps to lock bolts in place. BR
14. Install side bearing inner race with Tool.
ST

RS

BT

HA

EL

SE

IDX

PD-29
 ADJUSTMENT

To avoid confusion while calculating bearing shims, it is absolutely

necessary to stay with the metric system. If you measure anything
in inches, the results must be converted to the metric system.

Drive Pinion Height

1. First prepare Tools for pinion height adjustment.
H233B: q 1 Height gauge (ST31251000)
q
2 Dummy shaft (ST31181001)
q
3 Spacer [thickness: 2.50 mm (0.0984 in)]
q
4 Feeler gauge
H260: q 1 Height gauge (ST31130000)
q2 Dummy shaft (ST31241000)
q4 Feeler gauge
2. To simplify the job, make a chart, like the one below, to orga-
SPD758 nize your calculations.
HUNDREDTHS OF
LETTERS
A MILLIMETER
H: Head number
D′: Figure marked on dummy shaft
S: Figure marked on height gauge
N: Measuring clearance

3. Write the following numbers down the chart.

H: Head number

SPD542

D′: Figure marked on dummy shaft.

SPD759

PD-30
 ADJUSTMENT
Drive Pinion Height (Cont’d)
S: Figure marked on height gauge. GI

MA

EM

LC
SPD760

4. Place pinion rear bearing inner cone and Tools on gear carrier. EC
Tool number:
H233B ST31181001
H260 ST31241000 FE

CL

MT
SPD271-A
AT
5. Attach Tool (Height gauge) to gear carrier, and measure the
clearance between the height gauge tip and the dummy shaft
face. TF
Tool number:
H233B ST31251000
H260 ST31130000

FA

SPD272-A
RA
6. Substitute these values into the equation to calculate the thick-
ness of the washer.
If values signifying H, D′ and S are not given, regard them as BR
zero and calculate.
H233B:
T (Thickness of washer) ST
= N − [(H − D′ − S) x 0.01] + 3.05
H260:
T (Thickness of washer) RS
= N − [(H − D′ − S) x 0.01] + 2.55
PD444-A BT

HA

EL

SE

PD029
IDX

PD-31
 ADJUSTMENT
Drive Pinion Height (Cont’d)
Example (H233B):
N = 0.30
H=2
D′ = −1
S=0
T = N − [(H − D′ − S) x 0.01] + 3.05
= 0.30 − [{2 − (−1) − 0} x 0.01] + 3.05
(1) H ........................................................................ 2
−D′ ................................................................. −(−1)
3
−S ...................................................................... −0
3
(2) 3
x 0.01
0.03
(3) N ................................................................... 0.30
−0.03
0.27
(4) 0.27
+3.05
3.32
∴T = 3.32
7. Select the proper pinion height washer.
Drive pinion height adjusting washer:
Refer to SDS (PD-57, 56).
If you cannot find the desired thickness of washer, use washer
with thickness closest to the calculated value.
Example (H233B):
Calculated value ... T = 3.32 mm
Used washer ... T = 3.33 mm

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.

SPD005

PD-32
 ADJUSTMENT
Tooth Contact (Cont’d)
3. Hold companion flange steady by hand and rotate the ring gear GI
in both directions.

MA

EM

LC
SPD695
EC

FE

CL

MT

AT

TF

FA
SPD007-B

RA

BR

ST

RS

BT

HA

EL

SE

IDX

PD-33
 ASSEMBLY

Differential Case — 4-pinion type —

1. Measure clearance between side gear thrust washer and dif-
ferential case.
Clearance between side gear thrust washer
and differential case (A — B):
0.15 - 0.20 mm (0.0059 - 0.0079 in)
The clearance can be adjusted with side gear thrust washer.
Refer to SDS.
2. Apply oil to gear tooth surfaces and thrust surfaces and check
that they turn properly.

SPD656

3. Install differential case LH and RH.

SPD643

4. Place differential case on ring gear.

5. Apply locking sealer to ring gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.

SPD746

6. Press-fit side bearing inner races on differential case with Tool.

Tool number:
qA H233B ST33190000
H260 Drift
qB H233B ST02371000
H260 Drift

PD353

PD-34
 ASSEMBLY

Differential Case — 2-pinion type — GI

1. Install side gears, pinion mate gears and thrust washers into
differential case. MA

EM

LC
SPD552

2. Fit pinion mate shaft to differential case so that it meets lock pin EC
holes.
3. Adjust backlash between side gear and pinion mate gear by
selecting side gear thrust washer. Refer to SDS. FE
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and dif-
ferential case):
CL
0.15 - 0.20 mm (0.0059 - 0.0079 in)
MT
SPD258
AT
4. Install pinion mate shaft lock pin with a punch.
Make sure lock pin is flush with case.
TF

FA

SPD030
RA
5. Apply gear oil to gear tooth surfaces and thrust surfaces and
make sure they turn properly.
6. Install differential case assembly on ring gear. BR
Tighten bolts in a criss-cross pattern, lightly tapping bolt head
with a hammer.
ST

RS

SPD322 BT
7. Press-fit side bearing inner cones on differential case with Tool.
Tool number: HA
qA ST33190000
qB ST02371000
EL

SE

PD353
IDX

PD-35
 ASSEMBLY

Differential Carrier
1. Press-fit front and rear bearing outer races with Tools.
Tool number:
qA ST30611000
qB ST30621000 (front differential)
or suitable pipe
qC ST30701000 (H233B)
For H260, use suitable pipe.
CAUTION:
Do not damage roller side face.

SPD580

2. Select drive pinion height adjusting washer. Refer to ADJUST-

MENT (PD-30).
3. Install drive pinion height adjusting washer in drive pinion, and
press-fit pinion rear bearing inner cone in it, with press and
Tool.
Tool number: ST30911000

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 number:
q
A ST30720000
q
B KV38102510

SPD451A

PD-36
 ASSEMBLY
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
AT
8. Tighten pinion nut to the specified torque.
The threaded portion of drive pinion and pinion nut should be
free from oil or grease. TF
Tool number: KV38104700

FA

SPD040
RA
9. Turn drive pinion in both directions several times, and measure
pinion bearing preload.
Tool number: ST3127S000 BR
Pinion bearing preload (with front oil seal):
1.4 - 1.7 N⋅m (14 - 17 kg-cm, 12 - 15 in-lb)
If preload is out of specification, adjust the thickness of spacer and ST
shim combination by replacing shim and spacer with thinner one.
I Start from the combination of thickest spacer and shim.
I Combine each spacer and shim thickness one by one until the RS
correct specification are achieved.
Drive pinion bearing preload adjusting spacer and
SPD149
shim: BT
Refer to SDS (PD-56, 57).
HA

EL

SE

IDX

PD-37
 ASSEMBLY
Differential Carrier (Cont’d)
10. Install differential case assembly with side bearing outer races
into gear carrier.

PD383

11. Position side bearing adjusters on gear carrier with threads

properly engaged; screw in adjusters lightly at this stage of
assembly.
Tool number:
H233B ST32580000
H260 ST32530000

SPD684

12. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.
I 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:
H233B
0.15 - 0.20 mm (0.0059 - 0.0079 in)
H260
0.18 - 0.23 mm (0.0071 - 0.0091 in)
SPD246

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

tions several times to set bearing rollers.
Tool number: ST3127S000
Total preload (with front oil seal):
Drive pinion bearing
New parts
1.7 - 2.5 N⋅m (17 - 25 kg-cm, 15 - 22 in-lb)
Used parts
1.5 - 1.7 N⋅m (15 - 17 kg-cm, 13 - 15 in-lb)

SPD149

PD-38
 ASSEMBLY
Differential Carrier (Cont’d)
14. Tighten side bearing cap bolts. GI
15. Install side lock finger in place to prevent rotation during opera-
tion.
MA

EM

LC
SPD698

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

Runout limit: 0.08 mm (0.0031 in)
I If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the ring FE
gear and the differential case.
I If the backlash varies greatly when the runout of the ring gear
is within a specified range, the hypoid gear set or differential
CL
case should be replaced.
17. Check tooth contact. Refer to ADJUSTMENT (PD-30). MT
SPD247
AT

TF

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX

PD-39
DIFFERENTIAL LOCK

SPD441A

Actuator and Fork

SPD835-A

PD-40
 DIFFERENTIAL LOCK

Disassembly GI
1. Remove side bearing inner cone with Tool. For removal
procedure, refer to ordinary differential case. MA
2. Loosen ring gear bolts in a criss-cross pattern.
3. Tap ring gear off the gear with a soft hammer.
EM

LC
SPD839

4. Put marks on both differential cases. EC

5. Loosen screws on differential cases A and B using a press.
Tool number: ST33081000
6. Separate differential cases A and B. FE

CL

MT
SPD449A
AT
7. Drive out pinion mate shaft lock pin with Tool.
Draw out component parts.
TF

FA

SPD841
RA

BR

ST

RS

BT

HA

EL

SE

IDX

PD-41
 DIFFERENTIAL LOCK

Inspection

SPD842

CONTACT SURFACES
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
with oil stone.
q1 Differential case A
q2 Differential case B
q3 Side gear thrust washer
q4 Side gear
q5 Pinion mate thrust washer
q6 Pinion mate gear
q7 Pinion mate shaft

ACTUATOR OPERATION
Apply a vacuum pressure of 66.7 kPa (667 mbar, 500 mmHg, 19.69
inHg) and check its operation and leakage within 10 seconds.

SPD906

PD-42
 DIFFERENTIAL LOCK

Assembly GI
DIFFERENTIAL CASE
1. Install side gears, pinion mate gears and thrust washers into MA
differential case B.
2. Fit pinion mate shaft to differential case so that it meets lock pin
holes. EM

LC
SPD844

3. Adjust backlash between side gear and pinion mate gear. EC

I Opposite side of ring gear:
Select side gear thrust washer by measuring gap with feeler
gauge. Refer to SDS. FE

CL

MT
SPD845
AT
I Ring gear side:
Measure height H1.
Measure height H2. TF
H2 − H1 = Clearance between the side gear end face and dif-
ferential case B
Select side gear thrust washer. Refer to SDS.
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and dif-
ferential case): FA
0.10 - 0.20 mm (0.0039 - 0.0079 in)

RA

BR

ST

RS

SPD846 BT
4. Install pinion mate shaft lock pin with a punch. Make sure lock
pin is flush with case. HA
5. Install differential case A.
6. Place ring gear on differential case and install it by tightening
bolt. Use locking sealant. EL
7. Install side bearing inner cone.

SE

SPD847
IDX

PD-43
 DIFFERENTIAL LOCK
Assembly (Cont’d)
ACTUATOR
I If same differential carrier is used again, reuse actuator shim or
use a shim of the same thickness when used shim is damaged.

I When differential carrier is replaced with a new one, select

actuator shim to keep differential lock mechanism functioning.
I When installing the differential lock fork, make sure it is facing
the correct direction.

SPD848

1. Standard length “A” is between specified mounting surface of

actuator and differential case B surface “P”. Refer to SDS.

SPD930

2. Install differential carrier on axle case.

3. Rotate ring gear until surface “P” is seen through actuator
mounting hole in axle case.
Measure dimension “L” between actual mounting surface of
actuator on axle case and surface “P”, using suitable gauge
tool.
I Put gauge as shown on drawing.
I Put mark on gauge at actuator mounting surface.
I Measure dimension “L”.

SPD931

PD-44
 DIFFERENTIAL LOCK
Assembly (Cont’d)
4. If shim thickness determined by equation is assumed as “T”, “T” GI
will be expressed by equation “A” - “L”. Select a combination of
shims from those shown in SDS so that shim thickness is within
“T” range. Install actuator using selected shims. MA

EM

LC
SPD932
EC

FE

CL

MT

AT

TF

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX

PD-45
DIFFERENTIAL LOCK

System Description
The differential lock operates only in 4WD.
The differential lock control unit interrupts current flowing through
differential lock solenoid-2 when vehicle speed exceeds 7 km/h (4
MPH). If the differential lock switch is accidentally turned on when
vehicle speed is greater than 7 km/h (4 MPH), the control unit will
prevent the differential lock from sustaining impact damage.
A warning buzzer will sound when the vehicle is driven over 20
km/h (12 MPH) with the differential lock engaged.

SPD446A

PD-46
DIFFERENTIAL LOCK

Component Parts Location GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX
SPD442A

PD-47
DIFFERENTIAL LOCK

Wiring Diagram — DIFF/L —/LHD Models

TPD013

PD-48
DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —/LHD Models
(Cont’d) GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX
TPD014

PD-49
DIFFERENTIAL LOCK

Wiring Diagram — DIFF/L —/RHD Models

TPD016

PD-50
DIFFERENTIAL LOCK
Wiring Diagram — DIFF/L —/RHD Models
(Cont’d) GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX
TPD017

PD-51
 DIFFERENTIAL LOCK

Electrical Components Inspection

DIFFERENTIAL LOCK INDICATOR SWITCH CHECK
I Check switch function by checking continuity.
Continuity:
ON Continuity should exist.
OFF Continuity should not exist.
If NG, replace differential lock indicator switch.

SPD443A

DIFFERENTIAL LOCK SOLENOID CHECK

1. Disconnect differential lock solenoid 4-pin connector.
2. Check continuity between terminals q 1 and q
3 ,q2 and q
4 .
Continuity should exist.
If NG, replace differential lock solenoid.

SPD444A

SPEED SENSOR CHECK

Refer to EL section.

PD-52
 DIFFERENTIAL LOCK
Electrical Components Inspection (Cont’d)
DIFFERENTIAL LOCK CONTROL UNIT CHECK GI
On-vehicle check
MA
Be sure that vehicle is in 4WD.

H
EM
Operate vehicle at a speed less than 7 km/h (4 MPH) or
when stopping. LC

H
EC
Turn differential lock switch ON.

FE
H
Ensure differential lock indicator lamp is on. No Malfunction is in system other than differential lock con-
E
trol unit, speed sensor. Check and correct. CL
Yes
H
Turn differential lock switch OFF while driving vehicle at MT
speed less than 7 km/h (4 MPH) or when stopping.

AT
H
Drive vehicle at speed greater than 7 km/h (4 MPH) and
turn differential lock switch ON. TF

H
Ensure differential lock indicator lamp is on. Yes When speed sensor functions, differential lock control
E
unit functions improperly.
No
FA
H H
Differential lock control unit is functioning properly. Check differential lock control unit. RA

Unit check BR
1. Ensure that wiring to differential lock control unit is correct and
that the unit is properly connected to power supply.
2. Place vehicle on a safety stand properly. Ensure that the front ST
and rear wheels rotate freely.
RS

BT
3. Check output voltage of differential lock at solenoid-2 connec-
tor. HA
I Vehicle speed less than 7 km/h (4 MPH) on speedometer
Power supply: Approximately 12V
I Vehicle speed greater than 7 km/h (4 MPH) on speedometer EL
Output voltage: Approximately 0V

SE

IDX
SPD445A

PD-53
 SERVICE DATA AND SPECIFICATIONS (SDS)

Propeller Shaft
GENERAL SPECIFICATIONS
Front propeller shaft
Except for RD28 RD28 Engine MT
Applied model
Engine MT models models

Propeller shaft model 2F80B

Number of joints 2

Type of journal bearing Solid (Disassembly type)

Coupling type with trans-

Flange type
mission

Distance between yokes

73 (2.87)
mm (in)

Shaft length (Spider-to-

810 (31.89) 832 (32.76)
spider) mm (in)

Shaft outer diameter

50.8 (2.000)
mm (in)

Rear propeller shaft

Applied model

Engine TB45 TD42 TB42 RD28

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

Body Wagon Hardtop Wagon Hardtop Wagon

Propeller shaft model 2F100H 2F80B

Number of joints 2
Type of journal bearing Solid (Disassembly type)

Coupling type with trans-

Flange type
mission

Distance between yokes

94 (3.70) 94 (3.70) 94 (3.70) 94 (3.70) 94 (3.70) 73 (2.87) 73 (2.87) 73 (2.87)
mm (in)

Shaft length (Spider-to- 1,025 1,055 1,033

970 (38.19) 1,025 (40.35) 460 (18.11) 440 (17.32) 490 (19.29)
spider) mm (in) (40.35) (41.54) (40.67)

Shaft outer diameter 89.6 89.6 75.2 89.6 89.6 89.6

90 (3.54) 57 (2.24)
mm (in) (3.528) (3.528) (2.961) (3.528) (3.528) (3.528)

INSPECTION AND ADJUSTMENT Available snap rings

Service data 2F80B
Thickness mm (in) Color Part number
Propeller shaft model 2F80B, 2F100H
1.99 (0.0783) White 37146-C9400
Propeller shaft runout limit
0.6 (0.024)
mm (in) 2.02 (0.0795) Yellow 37147-C9400
Journal axial play mm (in) 0.02 (0.0008) 2.05 (0.0807) Red 37148-C9400

2.08 (0.0819) Green 37149-C9400

2.11 (0.0831) Blue 37150-C9400

2.14 (0.0843) Light brown 37151-C9400

2.17 (0.0854) Black 37152-C9400

2.20 (0.0866) Black 37153-C9400

PD-54
 SERVICE DATA AND SPECIFICATIONS (SDS)
Propeller Shaft (Cont’d)
2F100H GI
Thickness mm (in) Color Part number
1.95 (0.0768) White 37146-61502
MA
1.98 (0.0780) Yellow 37147-61502
2.01 (0.0791) Red 37148-61502
2.04 (0.0803) Green 37149-61502 EM
2.07 (0.0815) Blue 37150-61502
2.10 (0.0827) Light Brown 37151-61502
2.13 (0.0839) Pink 37146-61503 LC
2.16 (0.0850) Gold 37147-61503
2.19 (0.0862) Black 37148-61503
2.22 (0.0874) Color less 37149-61503 EC

Final Drive FE
GENERAL SPECIFICATIONS
Body type Wagon Hardtop CL
Engine RD28ETi TD42 TB42S TB45E RD28ETi TB42S
Transmission M/T A/T M/T
Standard MT
Front final drive H233B
2-pinion
Gear ratio 4.625 4.111 3.900 4.625 4.111 AT
Number of teeth (Ring
37/8 37/9 39/10 37/8 37/9
gear/drive pinion)
Oil capacity (Approx.)
5.4 (9-1/2)
TF
 (Imp pt)
Option- Stan- Option- Option- Stan- Option- Stan- Option- Stan- Option- Stan- Option-
Standard
al dard al al dard al dard al dard al dard al
Rear final drive
H233B H260 H233B
[Grade]
Diff. 4 pin- Diff. Diff. 4 pin- Diff. 4 pin- Diff. 4 pin- Diff. 4 pin- Diff.
4 pinion
lock ion lock lock ion lock ion lock ion lock ion lock
FA
Gear ratio 4.625 4.111 3.900 4.625 4.111
Number of teeth (Ring
37/8 37/9 39/10 37/8 37/9
gear/drive pinion)
RA
Without diff.
Oil capacity 2.4 (4-1/4) 4.7 (8-1/4) 2.4 (4-1/4)
lock
(Approx.)
 (Imp pt) With diff.
lock
3.0 (5-1/4) 3.7 (6-1/2) 3.0 (5-1/4) BR

With LSD model INSPECTION AND ADJUSTMENT (H233B) ST

Body type Wagon Hardtop Ring gear runout
Engine TB45E TD42 RD28ETi Ring gear runout limit mm (in) 0.08 (0.0031)
RS
Transmission A/T M/T M/T All M/T

Rear final drive H233B H260 H233B

Side gear adjustment (without LSD)
BT
[Grade] LSD
(H233B)
Gear ratio 3,900 4,111 4,625
Side gear backlash HA
Number of teeth (Clearance between side gear to 0.15 - 0.20 (0.0059 - 0.0079)
(ring gear/drive 39/10 37/9 37/8 differential case) mm (in)
pinion)
Available side gear thrust washers EL
Oil capacity
2.1 4.7 Thickness mm (in) Part number
(Approx.) 2.1 (3-3/4)
(3-3/4) (8-1/4)
 (Imp pt) 1.75 (0.0689) 38424-T5000 SE
1.80 (0.0709) 38424-T5001
1.85 (0.0728) 38424-T5002

IDX

PD-55
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont’d)
— Additional service for LSD model — Drive pinion preload adjustment (H233B)
(H233B) Drive pinion bearing preload adjust-
Adjusting shim and spacer
ing method
Differential torque adjustment
Drive pinion preload
Differential torque 108 - 137 N⋅m (kg-cm, in-lb)
N⋅m (kg-m, ft-lb) (11 - 14, 80 - 101)
Number of discs and plates 1.4 - 1.7
With front oil seal
(14 - 17, 12 - 15)
Friction disc 4
Friction plate 4 1.2 - 1.5
Spring plate 4 Without front oil seal
(12 - 15, 10 - 13)
Wear limit of plate and disc
0.1 (0.004) Available drive pinion preload adjusting shims
mm (in)
Allowable warpage of friction disc Thickness mm (in) Part number
0.08 (0.0031)
and plate mm (in)
2.31 (0.0909) 38125-82100
Available discs and plates
2.33 (0.0917) 38126-82100
Part name Thickness mm (in) Part number 2.35 (0.0925) 38127-82100
1.48 - 1.52 38433-C6000 2.37 (0.0933) 38128-82100
(0.0583 - 0.0598) (Standard type) 2.39 (0.0941) 38129-82100
Friction disc 2.41 (0.0949) 38130-82100
1.58 - 1.62 38433-C6001
(0.0622 - 0.0638) (Adjusting type) 2.43 (0.0957) 38131-82100
2.45 (0.0965) 38132-82100
1.48 - 1.52
Friction plate 38432-C6000 2.47 (0.0972) 38133-82100
(0.0583 - 0.0598)
2.49 (0.0980) 38134-82100
1.48 - 1.52
Spring disc 38436-C6000 2.51 (0.0988) 38135-82100
(0.0583 - 0.0598)
2.53 (0.0996) 38136-82100
1.48 - 1.52 2.55 (0.1004) 38137-82100
Spring plate 38435-C6010
(0.0583 - 0.0598) 2.57 (0.1012) 38138-82100
2.59 (0.1020) 38139-82100

Available drive pinion preload adjusting spacers

Drive pinion height adjustment (H233B)
Available pinion height adjusting washers Length mm (in) Part number

Thickness mm (in) Part number 4.50 (0.1772) 38165-76000

4.75 (0.1870) 38166-76000
2.58 (0.1016) 38151-01J00 5.00 (0.1969) 38167-76000
2.61 (0.1028) 38151-01J01 5.25 (0.2067) 38166-01J00
2.64 (0.1039) 38151-01J02 5.50 (0.2165) 38166-01J10
2.67 (0.1051) 38151-01J03
2.70 (0.1063) 38151-01J04
2.73 (0.1075) 38151-01J05 Total preload adjustment (H233B)
2.76 (0.1087) 38151-01J06
2.79 (0.1098) 38151-01J07 1.7 - 2.5
Total preload New
2.82 (0.1110) 38151-01J08 Drive pinion (17 - 25, 15 - 22)
N⋅m (kg-cm, in-lb)
2.85 (0.1122) 38151-01J09 bearing 1.5 - 1.7
With front oil seal Old
2.88 (0.1134) 38151-01J10 (15 - 17, 13 - 15)
2.91 (0.1146) 38151-01J11
2.94 (0.1157) 38151-01J12 0.15 - 0.20
Ring gear backlash mm (in)
2.97 (0.1169) 38151-01J13 (0.0059 - 0.0079)
3.00 (0.1181) 38151-01J14 Side bearing adjusting method Side adjuster
3.03 (0.1193) 38151-01J15
3.06 (0.1205) 38151-01J16
3.09 (0.1217) 38151-01J17 INSPECTION AND ADJUSTMENT (H260)
3.12 (0.1228) 38151-01J18
3.15 (0.1240) 38151-01J19 Ring gear runout
3.18 (0.1252) 38151-01J60
3.21 (0.1264) 38151-01J61 Ring gear runout limit mm (in) 0.08 (0.0031)
3.24 (0.1276) 38151-01J62
3.27 (0.1287) 38151-01J63 Side gear adjustment (without LSD) (H260)
3.30 (0.1299) 38151-01J64
3.33 (0.1311) 38151-01J65 Side gear backlash
3.36 (0.1323) 38151-01J66 (Clearance between side gear to 0.15 - 0.20 (0.0059 - 0.0079)
3.39 (0.1335) 38151-01J67 differential case) mm (in)
3.42 (0.1346) 38151-01J68
3.45 (0.1358) 38151-01J69 Available side gear thrust washers
3.48 (0.1370) 38151-01J70 Thickness mm (in) Part number
3.51 (0.1382) 38151-01J71
3.54 (0.1394) 38151-01J72 1.55 (0.0610) 38424-61500
3.57 (0.1406) 38151-01J73 1.60 (0.0630) 38424-61501
3.60 (0.1417) 38151-01J74 1.65 (0.0650) 38424-61502
3.63 (0.1429) 38151-01J75
3.66 (0.1441) 38151-01J76

PD-56
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont’d)
— Additional service for LSD model — Drive pinion preload adjustment (H260) GI
(H260) Drive pinion bearing preload adjust-
Adjusting shim and spacer
ing method
Differential torque adjustment MA
Drive pinion preload
Differential torque 157 - 186 N⋅m (kg-cm, in-lb)
N⋅m (kg-m, ft-lb) (16 - 19, 116 -137)

Number of discs and plates With front oil seal

1.4 - 1.7 EM
(14 - 17, 12 - 15)
Friction disc 4 1.2 - 1.5
Friction plate 4 Without front oil seal
Spring plate 4
(12 - 15, 10 - 13) LC
Available drive pinion preload adjusting shims
Wear limit of plate and disc
0.1 (0.004) Thickness mm (in) Part number
mm (in) EC
Allowable warpage of friction disc 2.31 (0.0909) 38125-82100
0.08 (0.0031) 2.33 (0.0917)
and plate mm (in) 38126-82100
2.35 (0.0925) 38127-82100
Side gear backlash (Clearance 2.37 (0.0933) 38128-82100
FE
between side gear and differential 0.05 - 0.20 (0.0020 - 0.0079) 2.39 (0.0941) 38129-82100
case) mm (in) 2.41 (0.0949) 38130-82100
Available discs and plates 2.43 (0.0957) 38131-82100 CL
2.45 (0.0965) 38132-82100
Part name Thickness mm (in) Part number 2.47 (0.0972) 38133-82100
2.49 (0.0980) 38134-82100
Friction disc
2.38 - 2.42
38433-C8700 2.51 (0.0988) 38135-82100
MT
(0.0937 - 0.0953)
2.53 (0.0996) 38136-82100
2.38 - 2.42 2.55 (0.1004) 38137-82100
38432-C8700
Friction plate
(0.0937 - 0.0953) 2.57 (0.1012) 38138-82100 AT
2.59 (0.1020) 38139-82100
2.48 - 2.52
38432-C8701
(0.0976 - 0.0992) Available drive pinion preload adjusting spacers
2.38 - 2.42 Length mm (in) Part number
TF
Spring plate 38435-76010
(0.0937 - 0.0953)
4.50 (0.1772) 38165-76000
4.75 (0.1870) 38166-76000
Drive pinion height adjustment (H260) 5.00 (0.1969) 38167-76000
Available pinion height adjusting washers

Thickness mm (in) Part number Total preload adjustment (H260) FA

2.60 (0.1024) 38153-82101 1.7 - 2.5
Total preload New
2.63 (0.1035) 38153-82102 Drive pinion (17 - 25, 15 - 22)
N⋅m (kg-cm, in-lb)
2.66 (0.1047) 38153-82103
With front oil seal
bearing 1.5 - 1.7 RA
2.69 (0.1059) 38153-82104 Old
(15 - 17, 13 - 15)
2.72 (0.1071) 38153-82105
2.75 (0.1083) 38153-82106 0.18 - 0.23
2.78 (0.1094) 38153-82107
Ring gear backlash mm (in)
(0.0071 - 0.0091) BR
2.81 (0.1106) 38153-82108
2.84 (0.1118) 38153-82109 Side bearing adjusting method Side adjuster
2.87 (0.1130) 38153-82110 ST
2.90 (0.1142) 38153-82111
2.93 (0.1154) 38153-82112
2.96 (0.1165) 38153-82113
2.99 (0.1177) 38153-82114 RS
3.02 (0.1189) 38153-82115
3.05 (0.1201) 38153-82116
3.08 (0.1213)
3.11 (0.1224)
38153-82117
38153-82118
BT
3.14 (0.1236) 38153-82119
3.17 (0.1248) 38153-82120
HA

EL

SE

IDX

PD-57