PROPELLER SHAFT & DIFFERENTIAL CARRIER SECTIONPD CONTENTS IDX. PROPELLER SHAFT...3 Preparation...3 C200. REAR FINAL DRIVE...40 Preparation...

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1 PROPELLER SHAFT & DIFFERENTIAL CARRIER SECTIONPD GI MA EM LC EC CONTENTS FE PROPELLER SHAFT...3 Preparation...3 SPECIAL SERVICE TOOLS...3 Noise, Vibration and Harshness (NVH) Troubleshooting...4 NVH TROUBLESHOOTING CHART...4 Components...5 FRONT PROPELLER SHAFT...5 REAR PROPELLER SHAFT...6 On-vehicle Service...7 PROPELLER SHAFT VIBRATION...7 APPEARANCE CHECKING...8 Removal and Installation...8 Inspection...9 Disassembly...9 CENTER BEARING...9 JOURNAL...10 Assembly...11 CENTER BEARING...11 JOURNAL...11 Service Data and Specifications (SDS)...13 GENERAL SPECIFICATIONS...13 SERVICE DATA...13 R200A FRONT FINAL DRIVE...14 Preparation...14 SPECIAL SERVICE TOOLS...14 Noise, Vibration and Harshness (NVH) Troubleshooting...16 On-vehicle Service...16 FRONT OIL SEAL REPLACEMENT...16 REAR COVER GASKET REPLACEMENT...17 Components...18 Removal and Installation...19 REMOVAL...19 INSTALLATION...19 Disassembly...20 PRE-INSPECTION...20 FINAL DRIVE HOUSING...20 DIFFERENTIAL CASE...23 DIFFERENTIAL SIDE SHAFT...24 Inspection...25 RING GEAR AND DRIVE PINION...25 DIFFERENTIAL CASE ASSEMBLY...25 BEARING...25 Adjustment...25 SIDE BEARING PRELOAD...26 PINION GEAR HEIGHT AND PINION BEARING PRELOAD...27 TOOTH CONTACT...31 Assembly...32 DIFFERENTIAL SIDE SHAFT...32 DIFFERENTIAL CASE...33 FINAL DRIVE HOUSING...34 Service Data and Specifications (SDS)...38 R200A...38 C200 REAR FINAL DRIVE...40 Preparation...40 SPECIAL SERVICE TOOLS...40 Noise, Vibration and Harshness (NVH) Troubleshooting...42 On-vehicle Service...43 FRONT OIL SEAL REPLACEMENT...43 REAR COVER GASKET REPLACEMENT...43 Components...44 Removal and Installation...45 REMOVAL...45 INSTALLATION...45 Disassembly...45 PRE-INSPECTION...45 DIFFERENTIAL CARRIER...46 DIFFERENTIAL CASE...48 Inspection...49 RING GEAR AND DRIVE PINION...49 DIFFERENTIAL CASE ASSEMBLY...49 BEARING...49 Adjustment...49 CL MT AT TF AX SU BR ST RS BT HA SC EL IDX

2 CONTENTS (Cont d) SIDE BEARING PRELOAD...50 PINION GEAR HEIGHT...51 TOOTH CONTACT...56 Assembly...57 DIFFERENTIAL CASE...57 DIFFERENTIAL CARRIER...58 Service Data and Specifications (SDS)...62 C H233B REAR FINAL DRIVE...64 Preparation...64 SPECIAL SERVICE TOOLS...64 Noise, Vibration and Harshness (NVH) Troubleshooting...66 On-vehicle Service...66 FRONT OIL SEAL REPLACEMENT...66 Components...68 Removal and Installation...69 REMOVAL...69 INSTALLATION...69 Disassembly...69 PRE-INSPECTION...69 DIFFERENTIAL CARRIER...70 DIFFERENTIAL CASE...72 Inspection...73 RING GEAR AND DRIVE PINION...73 DIFFERENTIAL CASE ASSEMBLY...73 BEARING...74 Limited Slip Differential...74 PREPARATION FOR DISASSEMBLY...74 DISASSEMBLY...74 INSPECTION...76 ADJUSTMENT...77 ASSEMBLY...78 Adjustment...80 PINION GEAR HEIGHT...80 TOOTH CONTACT...83 Assembly...84 DIFFERENTIAL CASE...84 DIFFERENTIAL CARRIER...86 Service Data and Specifications (SDS)...89 H233B...89 PD-2

3 PROPELLER SHAFT Preparation SPECIAL SERVICE TOOLS The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Preparation NGPD0001 GI Tool number (Kent-Moore No.) Tool name Description MA KV (J44195) Companion flange wrench Removing and installing propeller shaft lock nut, and drive pinion lock nut EM LC NT771 EC ST3090S000 ( ) Drive pinion rear inner race puller set 1 ST (J ) Puller 2 ST (J ) Base NT527 Removing and installing drive pinion rear inner cone a: 79 mm (3.11 in) dia. b: 45 mm (1.77 in) dia. c: 35 mm (1.38 in) dia. FE CL MT KV (J-45073) Rear axle shaft bearing puller Removing wheel bearing, wheel bearing lock nut and ABS sensor rotor AT TF LPD022 AX SU BR ST RS BT HA SC EL PD-3 IDX

4 PROPELLER SHAFT Noise, Vibration and Harshness (NVH) Troubleshooting Noise, Vibration and Harshness (NVH) Troubleshooting NVH TROUBLESHOOTING CHART Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. =NGPD0049 NGPD0049S01 Reference page PD-6 PD-7 PD-7 PD-25, 73 PD-31, 83 PD-25, 73 PD-20, 69 Refer to PROPELLER SHAFT in this chart. Refer to DIFFERENTIAL in this chart. Refer to NVH, AX-4 Refer to NVH, AX-4 Refer to NVH, SU-3 Refer to NVH, SU-3 Refer to NVH, SU-3 Refer to NVH, BR-5 Refer to NVH, ST-5 Possible cause and SUSPECTED PARTS Uneven rotation torque Center bearing improper installation Excessive center bearing axial end play Center bearing mounting (insulator) cracks, damage or deterioration Excessive joint angle Rotation imbalance Excessive runout Rough gear tooth Improper gear contact Tooth surfaces worn Incorrect backlash Companion flange excessive runout Improper gear oil PROPELLER SHAFT DIFFERENTIAL DRIVE SHAFT AXLE SUSPENSION TIRES ROAD WHEEL BRAKES STEERING Symptom : Applicable PROPEL- LER SHAFT DIFFER- ENTIAL Noise Shake Vibration Noise PD-4

5 FRONT PROPELLER SHAFT PROPELLER SHAFT Components Components NGPD0002 NGPD0002S01 GI MA EM LC EC FE CL MT AT TF WPD016 AX SU BR ST RS BT HA SC EL PD-5 IDX

6 Components (Cont d) REAR PROPELLER SHAFT PROPELLER SHAFT NGPD0002S02 WPD001 WPD002 PD-6

7 PROPELLER SHAFT Components (Cont d) GI MA EM LC EC FE CL MT AT WPD021 TF SPD356A On-vehicle Service PROPELLER SHAFT VIBRATION NGPD0003 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 propeller shaft by rotating final drive companion flange with hands. Runout limit: 0.6 mm (0.024 in) AX SU BR ST RS BT HA SC PD-7 EL IDX

8 On-vehicle Service (Cont d) PROPELLER SHAFT Propeller shaft runout measuring points: Unit: mm (in) Distance A B C 3S1310 (2WD, KA24DE) M/T 276 (10.87) 341 (13.43) 3S1310 (2WD, VG33E) A/T 243 (9.57) M/T 290 (11.42) 338 (13.31) 338 (13.31) 3S80B-2BJ (2WD, VG33ER) A/T 162 (6.38) 240 (9.45) 240 (9.45) M/T 162 (6.38) 240 (9.45) 240 (9.45) 2S1310 (4WD, Rear) All 474 (18.66) 2F1310 (4WD, Front) All 271 (10.67) WPD 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 NGPD0004 Inspect propeller shaft tube surface for dents or cracks. If damaged, replace propeller shaft assembly. If center bearing is noisy or damaged, replace center bearing. Removal and Installation NGPD0005 1) Put match marks on flanges and separate propeller shaft from final drive. SPD103 2) Remove propeller shaft. Insert plug into rear oil seal after removing rear propeller shaft. SPD359 PD-8

9 PROPELLER SHAFT Inspection Inspection NGPD0006 Inspect propeller shaft runout. If runout exceeds specifications, replace propeller shaft assembly. Runout limit: 0.6 mm (0.024 in) GI MA EM SPD106 If the play exceeds specifications, replace propeller shaft assembly. Journal axial play: 0.02 mm ( in) or less LC EC FE CL SPD874 Disassembly CENTER BEARING NGPD0007 NGPD0007S01 1. Put match marks on flanges, and separate 2nd tube from 1st tube. MT AT TF SPD Put match marks on the flange and shaft. AX SU BR ST SPD Remove locking nut with Tool. Tool number: KV (J44195) 4. Remove companion flange with puller. RS BT HA SC EL SPD475A PD-9 IDX

10 Disassembly (Cont d) PROPELLER SHAFT 5. Remove center bearing with Tool and press. Tool number: ST (J ) SPD113 JOURNAL 1. Put match marks on shaft and flange or yoke. NGPD0007S02 SPD Remove snap ring. APD Remove pushed out journal bearing by lightly tapping yoke with a hammer, taking care not to damage journal and yoke hole. SPD Remove bearing at opposite side in above operation. Put marks on disassembled parts so that they can be reinstalled in their original positions from which they were removed. SPD131 PD-10

11 PROPELLER SHAFT Assembly CENTER BEARING Assembly NGPD0008 NGPD0008S01 When installing center bearing, position the F mark on center bearing toward front of vehicle. Apply a coat of multi-purpose lithium grease containing molybdenum disulfide to the end face of the center bearing and both sides of the washer. GI MA EM SPD114 Stake the nut. Always use new one. Align match marks when assembling tubes. LC EC FE CL SPD117 JOURNAL NGPD0008S02 1. Assemble journal bearing. Apply recommended multi-purpose grease on bearing inner surface. When assembling, be careful that needle bearing does not fall down. MT AT TF WPD Install new snap rings. AX SU BR ST APD Adjust thrust clearance between bearing and snap ring to zero by tapping yoke. RS BT HA SC EL SPD732 PD-11 IDX

12 Assembly (Cont d) PROPELLER SHAFT 4. Check to see that journal moves smoothly and check for axial play. Axial play: 0.02 mm ( in) or less SPD874 PD-12

13 PROPELLER SHAFT Service Data and Specifications (SDS) Service Data and Specifications (SDS) GENERAL SPECIFICATIONS 2WD Model (KA24DE and VG33E Engines) Engine KA24DE VG33E Transmission M/T M/T A/T Propeller shaft model 3S1310 Number of joints 3 =NGPD0009 NGPD0009S01 GI MA EM Coupling method with transmission Type of journal bearings Sleeve type Solid type (disassembly type) LC Distance between yokes mm (in) 71 (2.80) 80 (3.15) Shaft length (Spider to spider) mm (in) Shaft outer diameter (in) mm 2WD Model (VG33ER Engine) 1st 640 (25.20) 665 (26.18) 570 (22.44) 2nd 687 (27.05) 684 (26.93) 1st 63.5 (2.50) 2nd 63.5 (2.50) Transmission M/T A/T Propeller shaft model 3S80B-2BJ Number of joints 3 NGPD0009S03 EC FE CL MT AT Coupling method with transmission Type of journal bearings Sleeve type Solid type (disassembly type) TF Distance between yokes mm (in) 80 (3.15) Shaft length (Spider to spider) mm (in) Shaft outer diameter 4WD Model mm (in) 1st 681 (26.81) 586 (23.07) 2nd 685 (26.97) 1st 75 (2.95) 2nd 65 (2.56) Location Front Rear Propeller shaft model 2F1310 2S1310 Number of joints 2 2 Coupling method with transmission Flange type Sleeve type Type of journal bearings Solid type (disassembly type) Distance between yokes mm (in) 71 (2.80) 80 (3.15) Shaft length (Spider to spider) mm (in) 522 (20.60) (37.57) Shaft outer diameter mm (in) 50.8 (2.0) 76.2 (3.0) SERVICE DATA Propeller shaft runout limit 0.6 (0.024) NGPD0009S02 NGPD0010 Unit: mm (in) AX SU BR ST RS BT HA SC Journal axial play 0.02 (0.0008) or less EL PD-13 IDX

14 Preparation FRONT FINAL DRIVE Preparation SPECIAL SERVICE TOOLS The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. R200A NGPD0013 Tool number (Kent-Moore No.) Tool name ST3127S000 (See J25765-A) Preload gauge 1 GG (J25765) Torque wrench 2 HT ( ) Socket adapter 3 HT ( ) Socket adapter KV (J34310, J ) Differential attachment Description NT124 Measuring pinion bearing preload and total preload Mounting final drive (To use, make a new hole.) a: 152 mm (5.98 in) KV (J44195) Companion flange wrench NT119 Removing and installing propeller shaft lock nut, and drive pinion lock nut ST3090S000 ( ) Drive pinion rear inner race puller set 1 ST (J ) Puller 2 ST (J ) Base ST3306S001 Differential side bearing puller set 1 ST (J ) Body 2 ST (J8107-2) Adapter KV (J25523) Differential side bearing drift NT771 NT527 NT072 Removing and installing drive pinion rear inner cone a: 79 mm (3.11 in) dia. b: 45 mm (1.77 in) dia. c: 35 mm (1.38 in) dia. Removing and installing differential side bearing inner cone a: 28.5 mm (1.122 in) dia. b: 38 mm (1.50 in) dia. Installing side bearing inner cone a: 54 mm (2.13 in) dia. b: 46 mm (1.81 in) dia. c: 32 mm (1.26 in) dia. NT085 PD-14

15 FRONT FINAL DRIVE R200A Preparation (Cont d) Tool number (Kent-Moore No.) Tool name Description GI KV (J25267) Side bearing spacer drift NT528 Installing side bearing spacer a: 8 mm (0.31 in) b: R42.5 mm (1.673 in) MA EM ST (J ) Drift Installing pinion rear bearing outer race (Use with ST or ST ) LC NT090 EC ST (J ) Drift Installing pinion rear bearing outer race (Use with ST ) a: 79 mm (3.11 in) dia. b: 59 mm (2.32 in) dia. FE CL ST (J ) Drift NT073 Installing pinion front bearing outer race (Use with ST ) a: 72 mm (2.83 in) dia. b: 48 mm (1.89 in) dia. MT AT KV (J25273) Gear carrier front oil seal drift NT073 Installing front oil seal a: 85 mm (3.35 in) dia. b: 60 mm (2.36 in) dia. TF NT115 AX KV (J26233) Gear carrier side oil seal drift NT120 Installing side oil seal SU BR (J34309) Differential shim selector Adjusting bearing pre-load and gear height ST RS BT NT134 HA (J ) Side bearing discs (2 Req d) Selecting pinion height adjusting washer SC NT136 EL PD-15 IDX

16 Preparation (Cont d) FRONT FINAL DRIVE R200A Tool number (Kent-Moore No.) Tool name Description (J8129) Spring gauge Measuring carrier turning torque NT127 Noise, Vibration and Harshness (NVH) Troubleshooting Refer to NVH TROUBLESHOOTING CHART, PD-4. NGPD0050 On-vehicle Service FRONT OIL SEAL REPLACEMENT (Front final drive: Model R200A) 1. Remove front propeller shaft. 2. Loosen drive pinion nut. Tool number: KV (J44195) NGPD0014 SPD476A 3. Remove companion flange. SPD Remove front oil seal. SPD735 PD-16

17 FRONT FINAL DRIVE R200A 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. 7. Install propeller shaft. Tool number: KV (J25273) GI MA EM SPD736 REAR COVER GASKET REPLACEMENT 1. Drain gear oil. 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. NGPD0015 LC EC FE CL SPD740-A MT AT TF AX SU BR ST RS BT HA SC EL PD-17 IDX

18 Components FRONT FINAL DRIVE Components R200A NGPD0016 WPD007 PD-18

19 SPD741 FRONT FINAL DRIVE Removal and Installation REMOVAL R200A Removal and Installation NGPD0017 NGPD0017S01 1) Remove propeller shaft. 2) Separate drive shaft from front final drive. Refer to AX-7, Drive Shaft. 3) Remove engine mounting bolts and raise up engine. 4) Remove front final drive together with differential mounting member. CAUTION: Be careful not to damage spline, sleeve yoke and front oil seal when removing propeller shaft. Before removing the final drive assembly or rear axle assembly, disconnect the ABS sensor harness connector from the assembly and move it away from the final drive/rear axle assembly area. Failure to do so may result in the sensor wires being damaged and the sensor becoming inoperative. GI MA EM LC EC FE CL INSTALLATION NGPD0017S02 1) Install front final drive assembly together with differential mounting member. MT AT TF SPD742 2) Tighten front final drive securing bolts and nuts by following the procedure to prevent drive train vibration. a) Temporarily tighten nut A. b) Temporarily tighten nut B. 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, 50 to 64 ft-lb). e) Tighten bolt A to the torque of 68 to 87 N m (6.9 to 8.9 kg-m, 50 to 64 ft-lb). f) Tighten bolt B to the torque of 68 to 87 N m (6.9 to 8.9 kg-m, 50 to 64 ft-lb). 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. 4) Install propeller shaft. Refer to Removal and Installation, PD-8. AX SU BR ST RS BT HA SC EL SPD743 PD-19 IDX

20 Disassembly SPD664 FRONT FINAL DRIVE Disassembly PRE-INSPECTION NGPD0018 NGPD0018S01 Before disassembling final drive, perform the following inspection. Total preload a) Turn drive pinion in both directions several times to set bearing rollers. b) Check total preload with Tool. Tool number: ST3127S000 (J25765-A) Total preload: N m (14-17 kg-cm, in-lb) R200A Ring gear to drive pinion backlash Check backlash of ring gear with a dial indicator at several points. Ring gear-to-drive pinion backlash: mm ( in) SPD513 Ring gear runout Check runout of ring gear with a dial indicator. Runout limit: 0.05 mm ( in) Tooth contact Check tooth contact. Refer to TOOTH CONTACT, PD-31. SPD524 Side gear to pinion mate gear backlash Using a feeler gauge, measure clearance between side gear thrust washer and differential case. Clearance between side gear thrust washer and differential case: Less than 0.15 mm ( in) SPD665 FINAL DRIVE HOUSING NGPD0018S02 1. Using three spacers [20 mm (0.79 in)], mount final drive assembly on Tool. Tool number: KV (J34310, J ) SPD666 PD-20

21 FRONT FINAL DRIVE 2. Remove differential side shaft assembly. R200A Disassembly (Cont d) GI MA EM SPD Remove differential side flange. LC EC FE CL SPD Put match marks on one side of side bearing cap with paint or punch to ensure that it is replaced in proper position during reassembly. Bearing caps are line-bored during manufacture and should be put back in their original places. MT AT TF SPD Remove side bearing caps. AX SU BR ST PD Remove differential case assembly with a pry bar. RS BT HA SC EL SPD668 PD-21 IDX

22 Disassembly (Cont d) FRONT FINAL DRIVE R200A 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. SPD Loosen drive pinion nut. Tool number: KV (J44195) 8. Remove companion flange with puller. 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. SPD Remove pinion bearing outer races with a brass drift. PD Remove pinion rear bearing inner cone and drive pinion height adjusting washer. Tool number: ST (J ) SPD209 PD-22

23 FRONT FINAL DRIVE R200A Disassembly (Cont d) DIFFERENTIAL CASE NGPD0018S03 1. Remove side bearing inner cones. To prevent damage to bearing, engage puller jaws in grooves. Tool number: A ST (J ) B ST (J8107-2) GI MA EM LC EC FE CL SPD529 Be careful not to confuse the right-hand and left-hand parts. Keep bearing and bearing race for each side together. MT AT TF SPD Loosen ring gear bolts in a crisscross pattern. 3. Tap ring gear off the differential case with a soft hammer. Tap evenly all around to keep ring gear from binding. AX SU BR ST SPD Punch off pinion mate shaft lock pin from ring gear side. Lock pin is caulked at pin hole mouth on differential case. RS BT HA SC EL SPD025 PD-23 IDX

24 Disassembly (Cont d) FRONT FINAL DRIVE R200A DIFFERENTIAL SIDE SHAFT NGPD0018S04 1. Cut collar with cold chisel. Be careful not to damage differential side shaft. SPD236A 2. Reinstall differential side shaft into extension tube and secure with bolts. Remove rear axle bearing by drawing out differential side shaft from rear axle bearing with puller. SPD Remove grease seal and oil seal. SPD647 SPD781 PD-24

25 FRONT FINAL DRIVE Inspection RING GEAR AND DRIVE PINION R200A Inspection NGPD0019 NGPD0019S01 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). GI MA EM DIFFERENTIAL CASE ASSEMBLY NGPD0019S02 Check mating surfaces of differential case, side gears, pinion mate gears, pinion mate shaft and thrust washers. LC EC FE CL SPD097AA BEARING 1. Thoroughly clean bearing. NGPD0019S03 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. MT AT TF SPD715 Adjustment NGPD0020 For quiet and reliable final drive operation, the following five adjustments must be made correctly: 1. Side bearing preload. Refer to Side Bearing Adjustment, PD Pinion gear height. Refer to Drive Pinion Height Adjustment, PD Pinion bearing preload. Refer to Drive Pinion Preload Adjustment, PD Ring gear-to-pinion backlash. Refer to Total Preload Adjustment, PD Ring and pinion gear tooth contact pattern. Refer to TOOTH CONTACT, PD-31. AX SU BR ST RS BT HA SC PD-25 EL IDX

26 Adjustment (Cont d) FRONT FINAL DRIVE R200A SIDE BEARING PRELOAD NGPD0020S01 A selection of carrier side bearing adjusting washer is required for successful completion of this procedure. 1. Make sure all parts are clean and that the bearings are well lubricated with light oil or DEXRON TM type automatic transmission fluid. 2. Place the differential carrier, with side bearings and bearing races installed, into the final drive housing. SPD 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. SPD Using Tool, install original carrier side bearing preload shims on the carrier end, opposite the ring gear. Tool number: KV (J25267) SPD Install the side bearing caps in their correct locations and torque the bearing cap retaining bolts. Specification: 88-98N m (9-10 kg-m, ft-lb) 6. Turn the carrier several times to seat the bearings. SPD Measure the turning torque of the carrier at the ring gear retaining bolts with a spring gauge, J8129. Specification: N ( kg, lb) of pulling force at the ring gear bolt SPD194A PD-26

27 SPD772 FRONT FINAL DRIVE R200A Adjustment (Cont d) 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 to side bearing. Side bearing adjustment: Refer to Side Bearing Adjustment, PD Record the total amount of washer thickness required for the correct carrier side bearing preload. 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 LC EC FE CL SPD668 PINION GEAR HEIGHT AND PINION BEARING PRELOAD NGPD0020S02 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 selector Tool, J MT AT TF SPD769 SPD197A Front Pinion Bearing make sure the J front pinion bearing seat is secured tightly against the J gauge anvil. Then turn the front pinion bearing pilot, J , to secure the bearing in its proper position. Rear Pinion Bearing the rear pinion bearing pilot, J , is used to center the rear pinion bearing only. The rear pinion bearing locking seat, J , is used to lock the bearing to the assembly. 3. Place the pinion preload shim selector Tool, J , gauge screw assembly with the pinion rear bearing inner cone installed into the final drive housing. AX SU BR ST RS BT HA SC EL SPD893 PD-27 IDX

28 Adjustment (Cont d) FRONT FINAL DRIVE R200A 4. Assemble the front pinion bearing inner cone and the J gauge anvil together with the J gauge screw in the final drive housing. Make sure that the pinion height gauge plate, J , will turn a full 360 degrees, and tighten the two sections together by hand. SPD199A 5. Turn the assembly several times to seat the bearings. SPD Measure the turning torque at the end of the J gauge anvil using torque wrench J25765A. Turning torque specification: N m (10-13 kg-cm, in-lb) SPD234A 7. Place the J 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 J gauge anvil and seat the small end squarely against the tip of the J gauge screw in the tool recessed portion. SPD209A PD-28

29 FRONT FINAL DRIVE R200A Adjustment (Cont d) GI MA EM SPD773 SPD210A 9. Select the correct thickness of pinion bearing preload adjusting washer using a standard gauge of 3.5 mm (0.138 in) and J feeler gauge. The exact measure is the thickness of the adjusting washer required. Select the correct washer. Drive pinion bearing preload adjusting washer: Refer to Drive Pinion Preload Adjustment, PD Set your selected, correct pinion bearing preload adjusting washer aside for use when assembling the pinion gear and bearings into the final drive. LC EC FE CL MT AT TF SPD774 PINION HEIGHT ADJUSTING WASHER SELECTION 11. Now, position the side bearing discs, J , and arbor firmly into the side bearing bores. AX SU BR ST SPD211A 12. Install the side bearing caps and tighten the cap bolts. Specification: 88-98N m (9-10 kg-m, ft-lb) RS BT HA SC EL SPD212A PD-29 IDX

30 Adjustment (Cont d) FRONT FINAL DRIVE R200A 13. Select the correct standard pinion height adjusting washer thickness by using a standard gauge of 3.0 mm (0.118 in) and your J feeler gauge. Measure the gap between the J R200A pinion height adapter and the arbor. 14. Write down the exact total measurement. SPD204A 15. Correct the pinion height washer size by referring to the pinion 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 second 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. SPD542 Pinion Head Height Number Add or Remove from the Standard Pinion Height Washer Thickness Measurement Add 0.06 mm ( in) Add 0.05 mm ( in) Add 0.04 mm ( in) Add 0.03 mm ( in) Add 0.02 mm ( in) Add 0.01 mm ( in) 0 Use the selected washer thickness +1 Subtract 0.01 mm ( in) +2 Subtract 0.02 mm ( in) +3 Subtract 0.03 mm ( in) +4 Subtract 0.04 mm ( in) +5 Subtract 0.05 mm ( in) +6 Subtract 0.06 mm ( in) 16. Select the correct drive pinion height washer. Drive pinion height adjusting washer: Refer to Drive Pinion Height Adjustment, PD-39. PD-30

31 FRONT FINAL DRIVE R200A Adjustment (Cont d) 17. Remove the J34309 pinion preload shim selector tool from the final drive housing and disassemble to retrieve the pinion bearings. GI MA EM SPD205A TOOTH CONTACT NGPD0020S03 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 pattern check, the most desirable contact for low noise level and long life can be assured. LC EC FE CL 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. MT AT TF SPD Hold companion flange steady by hand and rotate the ring gear in both directions. AX SU BR ST SPD677 RS BT HA SC PD-31 EL IDX

32 Adjustment (Cont d) FRONT FINAL DRIVE R200A SPD007-B Assembly DIFFERENTIAL SIDE SHAFT 1. Install oil seal and grease seal. Tool number: KV (J26233) NGPD0021 NGPD0021S01 SPD782-A SPD654-A 2. Install extension tube retainer, rear axle bearing and rear axle shaft bearing collar on differential side shaft. SPD655 PD-32

33 FRONT FINAL DRIVE R200A Assembly (Cont d) DIFFERENTIAL CASE NGPD0021S02 1. Install side gears, pinion mate gears and thrust washers into differential case. GI MA EM SPD552 SPD 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 differential case): Less than 0.15 mm ( in) 4. Install pinion mate shaft lock pin with a punch. Make sure lock pin is flush with case. LC EC FE CL MT AT TF SPD Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly. AX SU BR ST SPD Install differential case assembly on ring gear. 7. Apply locking agent [Loctite (stud lock) or equivalent] to ring gear bolts, and install them. Tighten bolts in a crisscross pattern. RS BT HA SC EL SPD554 PD-33 IDX

34 Assembly (Cont d) FRONT FINAL DRIVE R200A 8. Press-fit side bearing inner cones on differential case with Tool. Tool number: A KV (J25523) B ST (J8107-2) PD353 FINAL DRIVE HOUSING 1. Press-fit front and rear bearing outer races with Tools. Tool number: A ST (J ) B ST (J ) C ST (J ) NGPD0021S03 SPD Select drive pinion height adjusting washer and pinion bearing adjusting washer. Refer to PINION GEAR HEIGHT AND PIN- ION BEARING PRELOAD, PD 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: ST (J ) SPD Place pinion front bearing inner cone in final drive housing. SPD581 PD-34

35 FRONT FINAL DRIVE R200A Assembly (Cont d) 5. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install front oil seal. Tool number: KV (J25273) GI MA EM SPD Place drive pinion bearing spacer, drive pinion bearing adjusting washer and drive pinion in final drive housing. LC EC FE CL SPD Insert companion flange into drive pinion by tapping the companion flange with a soft hammer. MT AT TF SPD 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: KV (J44195) AX SU BR ST SPD478A SPD Turn drive pinion in both directions several revolutions, and measure pinion bearing preload. Tool number: ST3127S000 (J25765-A) Pinion bearing preload: N m (11-14 kg-cm, in-lb) When pinion bearing preload is outside the specifications, replace pinion bearing adjusting washer and spacer with a different thickness. PD-35 RS BT HA SC EL IDX

36 Assembly (Cont d) FRONT FINAL DRIVE R200A 10. Select side bearing adjusting washer. Refer to SIDE BEARING PRELOAD, PD Install differential case assembly with side bearing outer races into final drive housing. SPD Insert left and right side bearing adjusting washers in place between side bearings and final drive housing. SPD Drive in side bearing spacer with Tool. Tool number: KV (J25267) SPD Align mark on bearing cap with that on final drive housing and install bearing cap on final drive housing. SPD Apply multi-purpose grease to cavity at sealing lips of oil seal. Install side oil seal. Tool number: KV (J26233) SPD560 PD-36

37 FRONT FINAL DRIVE R200A Assembly (Cont d) 16. Measure ring gear-to-pinion backlash with a dial indicator. Ring gear-to-drive pinion backlash: mm ( in) 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. GI MA EM SPD Check total preload with Tool. When checking preload, turn drive pinion in both directions several times to set bearing rollers. Tool number: ST3127S000 (J25765-A) Total preload: N m (14-17 kg-cm, in-lb) LC EC FE CL SPD664 SPD561 SPD524 If preload is too great, remove the same amount of shim from each side. If preload is too small, add the same amount of shim to each side. Never add or remove a different number of shims for each side as it will change ring gear to drive pinion backlash. 18. Recheck ring gear-to-pinion backlash because increase or decrease in thickness of shims will cause change of ring gearto-pinion backlash. 19. Check runout of ring gear with a dial indicator. Runout limit: 0.05 mm ( in) If backlash varies excessively in different places, the variance may have resulted from foreign matter caught between the ring gear and the differential case. If the backlash varies greatly when the runout of the ring gear is within a specified range, the hypoid gear set or differential case should be replaced. 20. Check tooth contact. Refer to TOOTH CONTACT, PD Install rear cover and gasket. 22. Install differential side shaft assembly. MT AT TF AX SU BR ST RS BT HA SC EL SPD682 PD-37 IDX

38 Service Data and Specifications (SDS) R200A General Specifications FRONT FINAL DRIVE Service Data and Specifications (SDS) R200A =NGPD0022 Engine VG33E VG33ER Vehicle grade XE SE SC Standard Optional Standard Front final drive R200A 2-pinion Gear ratio Number of teeth (Ring gear/drive pinion) 51/11 49/10 49/10 51/11 Oil capacity (Approx.) (US pt, lmp pt) 1.75 (3-3/4, 3-1/8) Ring Gear Runout NGPD0023 Ring gear runout limit mm (in) 0.05 (0.0020) Side Gear Adjustment NGPD0024 Side gear backlash (Clearance between side gear and differential case) (in) Thickness mm (in) mm Less than 0.15 (0.0059) Part number* Available side gear thrust washers 0.75 (0.0295) 0.78 (0.0307) 0.81 (0.0319) 0.84 (0.0331) 0.87 (0.0343) 0.90 (0.0354) 0.93 (0.0366) N N N N N N N3116 *Always check with the Parts Department for the latest parts information. Side Bearing Adjustment NGPD0025 Differential carrier assembly turning resistance N (kg, lb) ( , ) Available side bearing adjusting washers Thickness mm (in) 2.00 (0.0787) 2.05 (0.0807) 2.10 (0.0827) 2.15 (0.0846) 2.20 (0.0866) 2.25 (0.0886) 2.30 (0.0906) 2.35 (0.0925) 2.40 (0.0945) 2.45 (0.0965) 2.50 (0.0984) 2.55 (0.1004) 2.60 (0.1024) Part number* N N N N N N N N N N N N N3112 *Always check with the Parts Department for the latest parts information. Total Preload Adjustment NGPD0026 Total preload N m (kg-cm, in-lb) (14-17, 12-15) Ring gear-to-pinion backlash mm (in) ( ) PD-38

39 Drive Pinion Height Adjustment Available pinion height adjusting washers Thickness mm (in) 3.09 (0.1217) 3.12 (0.1228) 3.15 (0.1240) 3.18 (0.1252) 3.21 (0.1264) 3.24 (0.1276) 3.27 (0.1287) 3.30 (0.1299) 3.33 (0.1311) 3.36 (0.1323) 3.39 (0.1335) 3.42 (0.1346) 3.45 (0.1358) 3.48 (0.1370) 3.51 (0.1382) 3.54 (0.1394) 3.57 (0.1406) 3.60 (0.1417) 3.63 (0.1429) 3.66 (0.1441) *Always check with the Parts Department for the latest parts information. Drive Pinion Preload Adjustment Drive pinion bearing preload adjusting method Part number* P P P P P P P P P P P P P P P P P P P P6036 Adjusting washer and spacer Drive pinion preload with front oil seal N m (kg-cm, in-lb) (11-14, ) Available drive pinion bearing preload adjusting washers Thickness mm (in) 3.81 (0.1500) 3.83 (0.1508) 3.85 (0.1516) 3.87 (0.1524) 3.89 (0.1531) 3.91 (0.1539) 3.93 (0.1547) 3.95 (0.1555) 3.97 (0.1563) 3.99 (0.1571) 4.01 (0.1579) 4.03 (0.1587) 4.05 (0.1594) 4.07 (0.1602) 4.09 (0.1610) Length mm (in) FRONT FINAL DRIVE R200A Service Data and Specifications (SDS) (Cont d) Part number* Part number* NGPD0027 NGPD0028 GI MA EM LC EC FE CL MT AT TF AX SU BR Available drive pinion bearing preload adjusting spacers (2.1457) (2.1575) (2.1693) (2.1811) (2.1929) (2.2047) B B B B B ST RS *Always check with the Parts Department for the latest parts information. BT HA SC EL PD-39 IDX

40 Preparation REAR FINAL DRIVE Preparation SPECIAL SERVICE TOOLS The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. C200 NGPD0052 Tool number (Kent-Moore No.) Tool name ST3127S000 (See J25765-A) Preload gauge 1 GG (J25765) Torque wrench 2 HT ( ) Socket adapter 3 HT ( ) Socket adapter KV (J44195) Companion flange wrench Description NT124 Measuring pinion bearing preload and total preload Removing and installing propeller shaft lock nut and drive pinion lock nut ST3090S000 ( ) Drive pinion rear inner race puller set 1 ST (J ) Puller 2 ST (J ) Base ST3306S001 Differential side bearing puller set 1 ST (J ) Body 2 ST (J8107-2) Adapter ST (J ) Differential side bearing drift NT771 NT527 NT072 Removing and installing drive pinion rear inner cone a: 79 mm (3.11 in) dia. b: 45 mm (1.77 in) dia. c: 35 mm (1.38 in) dia. Removing and installing differential side bearing inner cone a: 28.5 mm (1.122 in) dia. b: 38 mm (1.50 in) dia. Installing side bearing inner cone a: 51 mm (2.01 in) dia. b: 41 mm (1.61 in) dia. c: 28.5 mm (1.122 in) dia. ST ( ) Side bearing puller adapter NT085 Installing side bearing inner cone a: 43 mm (1.69 in) dia. b: 33.5 mm (1.319 in) dia. NT431 PD-40

41 REAR FINAL DRIVE C200 Preparation (Cont d) Tool number (Kent-Moore No.) Tool name Description GI KV (J25267) Side bearing spacer drift Installing side bearing spacer a: 8 mm (0.31 in) b: R42.5 mm (1.673 in) MA NT528 EM ST (J ) Drift Installing pinion rear bearing outer race LC NT090 EC ST (J ) Drift Installing pinion rear bearing outer race a: 79 mm (3.11 in) dia. b: 59 mm (2.32 in) dia. FE CL ST (J ) Drift NT073 Installing pinion front bearing outer race a: 72 mm (2.83 in) dia. b: 48 mm (1.89 in) dia. MT AT KV (J25273) Gear carrier front oil seal drift NT073 Installing front oil seal a: 85 mm (3.35 in) dia. b: 60 mm (2.36 in) dia. TF NT115 AX (J34309) Differential shim selector Adjusting bearing pre-load and gear height SU BR ST (J ) Side bearing discs (2 Req d) NT134 Selecting pinion height adjusting washer RS BT (J8129) Spring gauge NT136 Measuring carrier turning torque HA SC NT127 EL PD-41 IDX

42 Preparation (Cont d) REAR FINAL DRIVE C200 Tool number (Kent-Moore No.) Tool name KV381051S0 ( ) Rear axle shaft dummy 1 KV ( ) Torque wrench side 2 KV ( ) Vise side Description NT142 Checking differential torque on limited slip differential Noise, Vibration and Harshness (NVH) Troubleshooting NGPD0053 Refer to NVH TROUBLESHOOTING CHART, PD-4. PD-42

43 REAR FINAL DRIVE On-vehicle Service FRONT OIL SEAL REPLACEMENT C200 On-vehicle Service =NGPD Remove propeller shaft. Refer to Removal and Installation, PD Remove drive pinion nut. Tool number: KV (J44195) GI MA EM APD Remove companion flange. 4. Remove ABS sensor and sensor rotor. LC EC FE CL SPD Remove front oil seal. MT AT TF WPD Apply multi-purpose grease to cavity at sealing lips of oil seal. Press front oil seal into carrier. Tool number: KV (J25273) 7. Install ABS sensor and sensor rotor. 8. Install companion flange and drive pinion nut. 9. Install rear propeller shaft. AX SU BR ST WPD014 REAR COVER GASKET REPLACEMENT (Rear final drive: Model C200) 1. Drain gear oil. 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. NGPD0054 RS BT HA SC EL SPD740-A PD-43 IDX

44 Components REAR FINAL DRIVE Components C200 NGPD0055 WPD024 PD-44

45 REAR FINAL DRIVE Removal and Installation REMOVAL C200 Removal and Installation NGPD0056 NGPD0056S01 Remove propeller shaft. Refer to Removal and Installation, PD-8. Plug end of transfer case. Remove axle shaft. Refer to AX-32, REAR AXLE. CAUTION: Be careful not to damage spline, sleeve yoke and front oil seal when removing propeller shaft. Before removing the final drive assembly or rear axle assembly, disconnect the ABS sensor harness connector from the assembly and move it away from the final drive/ rear axle assembly area. Failure to do so may result in the sensor wires being damaged and the sensor becoming inoperative. GI MA EM LC EC FE CL INSTALLATION Fill final drive with recommended gear oil. NGPD0056S02 MT AT TF SPD123 PD245 Disassembly PRE-INSPECTION NGPD0057 NGPD0057S01 Before disassembling final drive, perform the following inspection. Total preload a) Turn drive pinion in both directions several times to set bearing rollers. b) Check total preload with Tool. Tool number: ST3127S000 (J25765-A) Total preload: N m (12-23 kg-cm, in-lb) Ring gear-to-drive pinion backlash. Check backlash of ring gear with a dial indicator at several points. Ring gear-to-drive pinion backlash: mm ( in) AX SU BR ST RS BT HA SC EL SPD196 PD-45 IDX

46 Disassembly (Cont d) REAR FINAL DRIVE Ring gear runout Check runout of ring gear with a dial indicator. Runout limit: 0.05 mm ( in) C200 SPD702 Tooth contact Check tooth contact. Refer to TOOTH CONTACT, PD-56. Side gear-to-pinion mate gear backlash Measure clearance between side gear thrust washer and differential case with a feeler gauge. Clearance between side gear thrust washer and differential case: Less than 0.15 mm ( in) SPD198 DIFFERENTIAL CARRIER 1. Drain gear oil. NGPD0057S02 2. Remove rear cover and rear cover gasket. 3. Put match marks on one side of side bearing cap with paint or punch to ensure that it is replaced in proper position during reassembly. Bearing caps are line-bored during manufacture and should be put back in their original places. SPD Remove side bearing caps. SPD Remove differential case assembly with pry bar. SPD193 PD-46

47 REAR FINAL DRIVE C200 Disassembly (Cont d) Keep the side bearing outer races together with their respective inner cones do not mix them up. GI MA EM SPD Remove pinion nut with Tool. Tool number: KV (J44195) LC EC FE CL APD Remove companion flange with puller. 8. Remove ABS sensor and sensor rotor. MT AT TF SPD Remove drive pinion with soft hammer. 10. Remove front oil seal and pinion front bearing inner cone. AX SU BR ST SPD Remove pinion bearing outer races with a brass drift. RS BT HA SC EL PD349 PD-47 IDX

48 Disassembly (Cont d) REAR FINAL DRIVE C Remove pinion rear bearing inner cone and pinion height adjusting washer. Tool number: ST (J ) PD179 DIFFERENTIAL CASE NGPD0057S03 1. Remove side bearing inner cones. To prevent damage to bearing, engage puller jaws in grooves. Tool numbers: A ST (J ) B ST (J8107-2) SPD529 Be careful not to confuse the right-hand and left-hand parts. SPD Loosen ring gear bolts in a crisscross fashion. 3. Tap ring gear off the differential case with a soft hammer. Tap evenly all around to keep ring gear from binding. SPD024 PD-48

49 REAR FINAL DRIVE C200 Disassembly (Cont d) 4. Punch off pinion mate shaft lock pin from ring gear side. Lock pin is caulked at pin hole mouth on differential case. GI MA EM SPD025 Inspection RING GEAR AND DRIVE PINION NGPD0058 NGPD0058S01 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). LC EC FE CL DIFFERENTIAL CASE ASSEMBLY NGPD0058S02 Check mating surfaces of differential case, side gears, pinion mate gears, pinion mate shaft, thrust block and thrust washers. MT AT TF SPD584 BEARING 1. Thoroughly clean bearing. NGPD0058S03 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. AX SU BR ST SPD715 Adjustment NGPD0059 For quiet and reliable final drive operation, the following five adjustments must be made correctly. 1. Side bearing preload. Refer to Side Bearing Adjustment, PD Pinion gear height. Refer to Drive Pinion Height Adjustment, PD Pinion bearing preload. Refer to Drive Pinion Preload Adjustment, PD Ring gear-to-pinion backlash. Refer to Total Preload Adjustment, PD-62. PD-49 RS BT HA SC EL IDX

50 Adjustment (Cont d) REAR FINAL DRIVE C Ring and pinion gear tooth contact pattern. Refer to TOOTH CONTACT, PD-56. SIDE BEARING PRELOAD NGPD0059S01 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 DEXRON automatic transmission fluid. 2. Place the differential carrier, with side bearings and bearing races installed, into the final drive housing. SPD 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. SPD Use Tool to place original carrier side bearing preload shims on the carrier end, opposite the ring gear. Tool number: KV (J25267) SPD Install the side bearing caps in their correct locations and torque the bearing cap retaining bolts. Specification: 88-98N m ( kg-m, ft-lb) 6. Turn the carrier several times to seat the bearings. SPD526 PD-50

51 REAR FINAL DRIVE C200 Adjustment (Cont d) 7. Measure the turning torque of the carrier at the ring gear retaining bolts with a spring gauge, J8129. Specification: N ( kg, lb) of pulling force at the ring gear bolt GI MA EM SPD194A SPD If the turning torque is not within the specifications, correct the torque as follows: 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 to side bearing. Side bearing adjustment: Refer to Side Bearing Adjustment, PD Record the total amount of washer thickness required for the correct carrier side bearing preload. 10. Remove the carrier from the final drive housing. Save the selected preload washers for later use during the assembly of the final drive unit. LC EC FE CL MT AT TF PD344 PINION GEAR HEIGHT NGPD0059S02 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 selector Tool, J AX SU BR ST SPD769 SPD197A Front pinion bearing make sure the J front pinion bearing seat is secured tightly against the J gauge anvil. Then turn the front pinion bearing pilot, J , to secure the bearing in its proper position. Rear pinion bearing the rear pinion bearing pilot, J , is used to center the rear pinion bearing only. The rear pinion bearing locking seat, J , is used to lock the bearing to the assembly. PD-51 RS BT HA SC EL IDX

52 Adjustment (Cont d) REAR FINAL DRIVE C Install the pinion rear bearing inner cone into the final drive housing. Then place the pinion preload shim selector Tool, J , on gauge screw assembly. SPD Assemble the front pinion bearing inner cone and the J gauge anvil. Assemble them together with the J gauge screw in the final drive housing. Make sure that the pinion height gauge plate, J , will turn a full 360 degrees. Tighten the two sections together by hand. SPD199A 5. Turn the assembly several times to seat the bearings. SPD Measure the turning torque at the end of the J gauge anvil using Tool. Tool number: ST3127S000 (J25765-A) Turning torque specification: N m (10-13 kg-cm, in-lb) SPD234A 7. Place the J pinion height adapter onto the gauge plate and tighten it by hand. CAUTION: Make sure all machined surfaces are clean. SPD208A PD-52

53 REAR FINAL DRIVE C200 Adjustment (Cont d) PINION BEARING PRELOAD WASHER SELECTION 8. Place the solid pinion bearing spacer, small end first, over the J gauge anvil and seat the small end squarely against the tip of the J gauge screw in the tool recessed portion. GI MA EM SPD209A LC EC FE CL SPD773 SPD210A 9. Select the correct thickness of pinion bearing preload adjusting washer using a standard gauge of 3.5 mm (0.138 in) and J feeler gauge. The exact measure is the thickness of the adjusting washer required. Select the correct washer. Drive pinion bearing preload adjusting washer: Refer to Drive Pinion Preload Adjustment, PD Set the selected, correct pinion bearing preload adjusting washer aside for use when assembling the pinion gear and bearings into the final drive. MT AT TF AX SU BR ST SPD774 PINION HEIGHT ADJUSTING WASHER SELECTION 11. Now, position the side bearing discs, J , and arbor firmly into the side bearing bores. Install the side bearing caps and tighten the cap bolts to proper torque. RS BT HA SC EL SPD211A PD-53 IDX

54 Adjustment (Cont d) REAR FINAL DRIVE C Select the correct standard pinion height adjusting washer thickness. Select by using a standard gauge of 3 mm (0.12 in) and J feeler gauge. Measure the distance between the J 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 pinion 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 determine the correct pinion height washer. SPD542 Use the following chart to determine the correct pinion height washer: Pinion head height number Add or remove from the standard pinion height washer thickness measurement Add 0.06 mm ( in) Add 0.05 mm ( in) Add 0.04 mm ( in) Add 0.03 mm ( in) Add 0.02 mm ( in) Add 0.01 mm ( in) 0 Use the selected washer thickness +1 Subtract 0.01 mm ( in) +2 Subtract 0.02 mm ( in) +3 Subtract 0.03 mm ( in) +4 Subtract 0.04 mm ( in) +5 Subtract 0.05 mm ( in) +6 Subtract 0.06 mm ( in) 15. Select the correct pinion height washer. Drive pinion height adjusting washer: Refer to Drive Pinion Height Adjustment, PD-63. PD-54

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