Differentials: Other Subaru Legacy BL/BP рестайлинг

REAR DIFFERENTIAL

When replacing a rear differential assembly, select the correct one according to the following table.

Note. Using a different rear differential assembly will cause the drive train and tires to drag or emit abnormal noise. For option code, refer to "ID" section. IDENTIFICATION , Identification .>

GENERAL SPECIFICATION

GENERAL SPECIFICATION

REAR DIFFERENTIAL GEAR OIL

Recommended gear oil

GL-5 (75W-90)

Note. Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.

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SERVICE DATA

SERVICE DATA SPECIFICATION

ADJUSTING PARTS

1. T-type (except for GT spec. B 6MT model)

PRELOAD ADJUSTING COLLAR AND LENGTH SPECIFICATION

PINION HEIGHT ADJUSTING WASHER AND THICKNESS SPECIFICATION

SIDE BEARING RETAINER SHIM AND THICKNESS SPECIFICATION

DRIVE PINION BEARING PRELOAD AND THICKNESS SPECIFICATION

1. T-type (GT spec. B 6MT model)

DRIVE PINION BEARING PRELOAD AND THICKNESS SPECIFICATION

1. VA1-type

PRELOAD ADJUSTING COLLAR AND LENGTH SPECIFICATION

PRELOAD ADJUSTING WASHER AND THICKNESS SPECIFICATION

DRIVE PINION BEARING PRELOAD AND THICKNESS SPECIFICATION

1. VA2-type

PRELOAD ADJUSTING COLLAR AND LENGTH SPECIFICATION

PRELOAD ADJUSTING WASHER AND THICKNESS SPECIFICATION

DRIVE PINION BEARING PRELOAD AND THICKNESS SPECIFICATION

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CAUTION

1. Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust and dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
5. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
6. Use SUBARU genuine gear oil, grease or the equivalent. Do not mix gear oil, grease, etc. of different grades or manufacturers.
7. Be sure to tighten fasteners including bolts and nuts to the specified torque.
8. Place shop jacks or rigid racks at the specified points.
9. Apply gear oil onto sliding or revolving surfaces before installation.
10. Before installing the O-ring or snap ring, apply a sufficient amount of gear oil to avoid damage and deformation.
11. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise.
12. Avoid damaging the mating surface of the case.

GENERAL TOOL

GENERAL TOOL

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1. Remove the filler plug, and then check the gear oil. Replace the gear oil if it is contaminated or deteriorated. REPLACEMENT, Differential Gear Oil .>
2. Check that the gear oil level is up to the bottom of the filler plug hole. If the level is low, refill up to the bottom of filler plug. Except for VA2-type VA2-type

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1. Lift the vehicle.
2. Remove the oil drain plug and filler plug, and drain the gear oil. CAUTION: Be careful not to burn your hands, because gear oil becomes extremely hot after running. Except for VA2-type VA2-type
3. Tighten the oil drain plug. NOTE: Apply liquid gasket to the drain plug for the T-type (except for GT spec. B 6MT model). Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Use a new copper gasket for the VA1-type and T-type (GT spec. B 6MT model). Use a new metal gasket for the VA2-type. Tightening torque: T-type (except for GT spec. B 6MT model): 49 N.m (5.0 kgf-m, 36.2 ft-lb) T-type (GT spec. B 6MT model): 60 N.m (6.1 kgf-m, 44.3 ft-lb) VA1-type: 34 N.m (3.5 kgf-m, 25.1 ft-lb) VA2-type: 29 N.m (3.0 kgf-m, 21.4 ft-lb)
4. Fill the differential carrier with gear oil to the bottom of filler plug. NOTE: Carefully refill oil while watching the level. Excessive or insufficient oil must be avoided. Recommended gear oil: SPECIFICATION, General Description .> Oil capacity: Except for GT spec. B 6MT model: 0.8 l (0.8 US qt, 0.7 lmp qt) GT spec. B 6MT model: 1.0 l (1.1 US qt, 0.9 lmp Except for VA2-type VA2-type
5. Install the filler plug. NOTE: Apply liquid gasket to the drain plug for the T-type (except for GT spec. B 6MT model). Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Use a new copper gasket for the VA1 -type and T-type (GT spec. B 6MT model). Use a new metal gasket for the VA2-type. Tightening torque: T-type (except for GT spec. B 6MT model): 49 N.m (5.0 kgf-m, 36.2 ft-lb) T-type (GT spec. B 6MT model): 60 N.m (6.1 kgf-m, 44.3 ft-lb) VA1-type: 34 N.m (3.5 kgf-m, 25.1 ft-lb) VA2-type: 29 N.m (3.0 kgf-m, 21.4 ft-lb)

AT MODEL

1. 4AT For front differential of 4AT model, refer to MAT" section. FRONT DIFFERENTIAL ASSEMBLY .>
2. 5AT For front differential of 5AT model, refer to "5AT" section. FRONT DIFFERENTIAL ASSEMBLY .>

MT MODEL

For front differential of the manual transmission, refer to "5MT" or "6MT" section. FRONT DIFFERENTIAL ASSEMBLY . >

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1. Disconnect the ground cable from the battery.
2. Shift the select lever or gear shift lever to neutral.
3. Release the parking brake.
4. Lift the vehicle.
5. Remove the rear exhaust pipe and muffler. 2.0 L SOHC and DOHC non-turbo model REAR EXHAUST PIPE .> MUFFLER .> 2.0 L DOHC turbo model REAR EXHAUST PIPE .> 3.0 L DOHC non-turbo model REAR EXHAUST PIPE .>
6. Remove the heat shield cover.
7. Remove the propeller shaft. REMOVAL , Propeller Shaft .>
8. Prepare the transmission jack and band.
9. Loosen the self-lock nuts which hold the rear differential to rear crossmember.
10. Remove the DOJ of rear drive shaft from rear differential using ST. ST 28099PA100 DRIVE SHAFT REMOVER
11. Remove the rear differential front member.
12. Support the rear differential with the transmission jack.
13. Secure the rear differential using band.
14. Remove the self-lock nuts which hold the rear differential to the crossmember.
15. Remove the rear differential stud bolt from rear crossmember bushing. NOTE: When removing the stud bolt, carefully adjust the angle and location of transmission jack and jack stand, if necessary.
16. Lower the transmission jack stand after removing the rear differential stud bolt from the rear crossmember. Rear drive shaft should not come into contact with the lateral link bolt.
17. Pull out the axle shaft from rear differential. NOTE: If it is difficult to remove the axle shaft from the rear differential, remove it using a ST. ST 28099PA100 DRIVE SHAFT REMOVER
18. Lower the transmission jack.
19. Secure the rear drive shaft to lateral link using wire.
20. Remove the rear differential member plate from rear differential.

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1. Install the rear differential member plate to the rear differential.
2. Set the rear differential to transmission jack. NOTE: Secure the rear differential to transmission jack using band.
3. Attach the ST to rear differential. ST 28099PA090 OIL SEAL PROTECTOR
4. Insert the spline shaft until the spline portion comes inside the side oil seal.
5. Remove ST from rear differential. ST 28099PA090 OIL SEAL PROTECTOR
6. Push the rear differential to insert the axle shaft into rear differential.
7. Adjust the transmission jack, if necessary, and insert the rear differential stud bolt into rear cross-member bushing properly.
8. After inserting the rear differential stud bolt into the rear crossmember bushing, lift up the transmission jack and align the rear differential to its attachment position.
9. Tighten a new self-locking nut temporarily to rear crossmember.
10. Remove the band from rear differential. Lift up the rear differential until the rear differential is separated from the transmission jack.
11. Install the rear differential front member with a new self-locking nut. Tightening torque: T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb) T2: 11 0 N.m (11.2 kgf-m, 81 ft-lb)
12. Tighten the self-locking nut. Tightening torque: 70 N.m (7.1 kgf-m, 51 ft-lb)
13. Lower the transmission jack.
14. Install the propeller shaft. INSTALLATION , Propeller Shaft .>
15. Install the heat shield cover.
16. Install the rear exhaust pipe and muffler.
17. After installing the rear differential carrier to the vehicle, remove the filler plug, and refill with gear oil up to the lower lip of the plug hole. Oil capacity: Except for GT spec. B 6MT model: 0.8 l (0.8 US qt, 0.7 imp qt) GT spec. B 6MT model: 1.0 l (1.1 US qt, 0.9 lmp qt)
18. Tighten the filler plug. NOTE: Apply liquid gasket to the plug. (Except for GT spec. B 6MT model) Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Use a new copper gasket. (GT spec. B 6MT model) Tightening torque: Except for GT spec. B 6MT model: 49 N.m (5.0 kgf-m, 36.2 ft-lb) GT spec. B 6MT model: 60 N.m (6.1 kgf-m, 44.3 ft-lb)

EXCEPT FOR GT SPEC. B 6MT MODEL

Note. Assemble in the reverse order of disassembly. Check and adjust each part during assembly. Keep the shims and washers in order, so that they are not improperly installed. Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed. Apply gear oil when installing the bearings and thrust washers. Be careful not to mix up the RH and LH bearing races. Use a new O-ring and gasket. Replace the oil seal with a new part at every disassembly. Apply grease to the oil seal lip. Be careful not to mix up the differential oil seal RH and LH.

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1. Adjusting preload for front and rear bearings NOTE: Adjust the bearing preload between front and rear bearings with collar and washer. Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted. Install the rear bearing race (rear) into the differential carrier using ST1 and ST2. ST1 398477701 HANDLE ST2 398477703 DRIFT 2 Install the rear bearing race (front) into the differential carrier using ST1 and ST2. ST1 398477701 HANDLE ST2 398477702 DRIFT Insert the ST1 into carrier with the pinion height adjusting washer and rear bearing cone fitted onto it. NOTE: If tooth contact is normal in the inspection before disassembling, verify that the washer is not deformed, and then re-use the used washer. Use new rear bearing cone. Install the preload adjusting collar & washer, front bearing cone, ST2, companion flange, and washer & self-locking nut. ST1 398507702 DUMMY SHAFT ST2 398507703 DUMMY COLLAR Turn the ST1 by hand to smooth the bearing, and tighten the self-locking nut while measuring the initial load or initial torque with a spring scale or torque wrench. Select the preload adjusting washer and collar so that the specified preload is obtained when nut is tightened to the specified torque. NOTE: Use a new self-locking nut. Be careful not to give excessive preload. When tightening the self-locking nut, lock ST1 with ST2 as shown in the figure. ST1 398507704 BLOCK ST2 398507702 DUMMY SHAFT Tightening torque: 181.5 N.m (18.5 kgf-m, 134.0 ft-lb) Initial load: 17.7 - 38.8 N (1.8 - 4.0 kgf, 4.0 - 8.7 lb) Initial torque: 0.67 - 1.47 N.m (0.07 - 0.15 kgf-m, 0.49 - 1.08 ft-lb) PRELOAD ADJUSTING WASHER AND THICKNESS SPECIFICATION Preload adjusting washer Part No. Thickness mm (in) 383705200 2.59 (0.1020) 383715200 2.57 (0.1012) 383725200 2.55 (0.1004) 383735200 2.53 (0.0996) 383745200 2.51 (0.0988) 383755200 2.49 (0.0980) 383765200 2.47 (0.0972) 383775200 2.45 (0.0965) 383785200 2.43 (0.0957) 383795200 2.41 (0.0949) 383805200 2.39 (0.0941) 383815200 2.37 (0.0933) 383825200 2.35 (0.0925) 383835200 2.33 (0.0917) 383845200 2.31 (0.0909) PINION ADJUSTING COLLAR AND THICKNESS SPECIFICATION Preload adjusting collar Part No. Thickness mm (in) 383695201 56.2 (2.213) 383695202 56.4 (2.220) 383695203 56.6 (2.228) 383695204 56.8 (2.236) 383695205 57.0 (2.244) 383695206 57.2 (2.252)
2. Adjusting drive pinion height: Adjust the drive pinion height with washer installed between the rear bearing cone and the back of pinion gear. Attach the ST2. ST1 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE ST3 398507703 DUMMY COLLAR Measure the clearance N between the end of ST2 and the end surface of ST1 by using a thickness gauge. NOTE: Make sure there is no clearance between the case and ST2. ST1 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed washer with this one. T = To + N - (H x 0.01) - 0.20 mm (0.008 in) NOTE: Use copies of this page. PINION HEIGHT ADJUSTING WASHER AND THICKNESS SPECIFICATION T Thickness of pinion height adjusting washer mm (in) To Thickness of washer temporally inserted mm (in) N Clearance of thickness gauge mm (in) H Figure marked on drive pinion head Memo: (Example of calculation) To = 2.20 + 1.20 = 3.40 mm N = 0.23 mm H = +1 T = 3.40 + 0.23 - 0.01 - 0.20 = 3.42 Result: Thickness = 3.42 mm Therefore, use WASHER 383605200. PINION HEIGHT ADJUSTING WASHER AND THICKNESS SPECIFICATION Pinion height adjusting washer Part No. Thickness mm (in) 383495200 3.09 (0.1217) 383505200 3.12 (0.1228) 383515200 3.15 (0.1240) 383525200 3.18 (0.1252) 383535200 3.21 (0.1264) 383545200 3.24 (0.1276) 383555200 3.27 (0.1287) 383565200 3.30 (0.1299) 383575200 3.33 (0.1311) 383585200 3.36 (0.1323) 383595200 3.39 (0.1335) 383605200 3.42 (0.1346) 383615200 3.45 (0.1358) 383625200 3.48 (0.1370) 383635200 3.51 (0.1382) 383645200 3.54 (0.1394) 383655200 3.57 (0.1406) 383665200 3.60 (0.1417) 383675200 3.63 (0.1429) 383685200 3.66 (0.1441)
3. Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST. ST 398177700 INSTALLER
4. Insert the drive pinion into the differential carrier, and install the preselected bearing preload adjusting collar and washer.
5. Press-fit the front bearing cone into case with ST1, ST2 and ST3. ST1 398507703 DUMMY COLLAR ST2 399780104 WEIGHT ST3 899580100 INSTALLER
6. Insert the collar, then press-fit the pilot bearing with ST1 and ST2. ST1 399780104 WEIGHT ST2 899580100 INSTALLER
7. Fit a new oil seal with ST. NOTE: Press-fit until the oil seal end comes 1 mm (0.04 in) inward from end of carrier. Apply grease to the oil seal lips. ST 498447120 INSTALLER
8. Press-fit the companion flange with ST1 and ST2. NOTE: Be careful not to damage the bearing. ST1 899874100 INSTALLER ST2 399780104 WEIGHT
9. Attach a new self-locking nut and tighten using the ST. ST 498427200 FLANGE WRENCH Tightening torque: 181.5 N.m (18.5 kgf-m, 134.0 ft-lb)
10. Check the initial torque and initial load. Initial load: 17.7 - 38.8 N (1.8 - 4.0 kgf, 4.0 - 8.7 lb) Initial torque: 0.67 - 1.47 N.m (0.07 - 0.15 kgf-m, 0.49 - 1.08 ft-lb)
11. Install the driven gear to the differential case. NOTE: Before installing bolts, apply seal material to bolt threads. SEAL MATERIAL THREE BOND 1324 (Part No. 004403042) or equivalent NOTE: Tighten diagonally while tapping the bolt heads. Tightening torque: 103 N.m (10.5 kgf-m, 76 ft-lb)
12. Press the side bearing into differential case using ST. ST 398487700 DRIFT
13. Press the side bearing race into side bearing retainer using the ST. ST 398417700 DRIFT PUNCH
14. Adjusting the side bearing retainer shims The driven gear backlash and side bearing preload can be adjusted by the side bearing retainer shim thickness. Install the differential case assembly into differential carrier in the reverse order of disassembly. Install the side bearing retainer shims to retainers RH and LH from which they were installed. NOTE: Replace broken or corroded side retainer shims and O-rings with a new part of the same thickness. SIDE BEARING RETAINER SHIM AND THICKNESS SPECIFICATION Side bearing retainer shim Part No. Thickness mm (in) 383475201 0.20 (0.0079) 383475202 0.25 (0.0098) 383475203 0.30 (0.0118) 383475204 0.40 (0.0157) 383475205 0.50 (0.0197) Align the arrow mark on differential carrier with the mark on side retainer during installation. NOTE: Replace the broken or cracked O-ring with a new part. Be careful that side bearing race is not damaged by the bearing roller. Tighten the side bearing retainer bolts. Tightening torque: 10.5 N.m (1.1 kgf-m, 7.7 ft-lb) Measure the driven gear to drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with the tooth surface of hypoid driven gear, and move the hypoid driven gear while securing the drive pinion. Read the value indicated on dial gauge. If the backlash is not within the range of specifications, adjust the side bearing retainer shim using the following procedures. When backlash exceeds 0.2 mm (0.008 in): Reduce the hypoid driven gear rear face shim thickness and increase the hypoid driven gear tooth surface side shim thickness. When backlash is less than 0.1 mm (0.004 in): Increase the hypoid driven gear rear face shim thickness and reduce the tooth surface side shim thickness. Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in) At the same time, measure the preload increase amount of the drive pinion. Compared with the resistance when differential case is not installed, if the total preload is not within specification, adjust the thickness of side bearing retainer shims, increasing/reducing both shims by an even amount at a time. Total preload: 20.7 - 54.4 N (2.1 - 5.5 kgf, 4.7 - 12.2 lb)
15. Recheck the driven gear to pinion backlash. Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
16. Check the driven gear runout on its back surface, and make sure that the pinion and driven gear rotate smoothly. Driven gear rear face runout limit: 0.05 mm (0.002 in)
17. Checking and adjusting the tooth contact of driven gear Apply an even coat of red lead on both sides of three or four teeth on the driven gear. Check the contact pattern after rotating the driven gear several revolutions back and forth until a definite contact pattern appears on the driven gear. When the contact pattern is not correct, readjust. NOTE: Be sure to wipe off the red lead completely after the adjustment is completed. Correct tooth contact Check item: Tooth contact pattern is slightly shifted towards the toe side under no-load rotation. (When driving, it moves towards the heel side.) Face contact Check item: Backlash is too large. Contact pattern Corrective action: Increase the thickness of pinion height adjusting washer according to the procedure for bringing the drive pinion close to the driven gear. Flank contact Check item: Backlash is too small. Contact pattern Adjustment: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive the pinion away from driven gear. Toe contact (inner side contact) Check item: Contact area is too small. Contact pattern Adjustment: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive the pinion away from driven gear. Heel contact (outside end contact) Check item: Contact area is too small. Contact pattern Corrective action: Increase thickness of pinion height adjusting washer according to the procedures for moving the drive pinion closer to the driven gear.
18. If proper tooth contact is not obtained, once again adjust the drive pinion height by changing the RH and LH side bearing retainer shims and the hypoid gear backlash. Drive pinion height ST1 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE T = To + N - (H x 0.01) - 0.20 (mm) Place: T = Thickness of pinion height adjusting washer (mm) To = Thickness of washer temporally inserted (mm) N = Clearance of thickness gauge (mm) H = Figure marked on drive pinion head Hypoid gear backlash Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
19. Remove the RH and LH side bearing retainer.
20. Install O-rings and side bearing retainer shims to side bearing retainers of both sides.
21. Install oil seals to side bearing retainers of both sides. REPLACEMENT, Rear Differential Side Oil Seal .>
22. Align the arrow mark on differential carrier with the mark on side retainer during installation.
23. Apply liquid gasket to the bolts indicated by the arrows, and tighten the side bearing retainer bolts. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Tightening torque: 10.5 N.m (1.1 kgf-m, 7.7 ft-lb)
24. Install the new gasket and rear cover, and tighten the bolts to the specified torque. Tightening torque: 29.5 N.m (3.0 kgf-m, 21.8 ft-lb)
25. Install the air breather cap.
26. Install the drain plug and filler plug. Tightening torque: 49 N.m (5.0 kgf-m, 36.2 ft-lb)

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1. Assembling instructions: Assemble in the reverse order of disassembly. Check and adjust each part during assembly. Keep the shims and washers in order, so that they are not improperly installed. Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed. Apply gear oil when installing the bearings and thrust washers. Be careful not to mix up the RH and LH bearing races. Replace the oil seal with a new part at every disassembly. Apply chassis grease between the lips. Adjust the bearing preload between front and rear bearings with spacer and washer. Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted.
2. Using the ST, press-fit the rear bearing race to the differential carrier. ST 398417700 DRIFT PUNCH
3. Using the ST, press-fit the front bearing race to the differential carrier. ST 398477702 DRIFT
4. Selection of pinion height adjusting washer Measure the thickness of the inserted pinion height adjusting washer. Read the stamps of the attached drive pinion gear and a new part. NOTE: When there is no stamp, it indicates 0 (zero). Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the installed washer with this one. T = T1 + (T2 x 0.01 - T3 x 0.01) PINION HEIGHT ADJUSTING WASHER AND THICKNESS SPECIFICATION T mm Thickness of the selected pinion height adjusting washer T1 mm Thickness of the inserted pinion height adjusting washer T2 mm Numbers stamped on the attached drive pinion gear T3 mm Numbers stamped on a new drive pinion gear (Example of calculation) T1 = 3.30, T2 = +2, T3 = -1 T = 3.30 + {(2 x 0.01) - (-1 x 0.01)} = 3.33 Result: Thickness = 3.33 mm A washer to be used is 38336AA310. PINION HEIGHT ADJUSTING WASHER AND THICKNESS SPECIFICATION Pinion height adjusting washer Part No. Thickness mm (in) 38336AA230 3.09 (0.1217) 38336AA240 3.12 (0.1228) 38336AA250 3.15 (0.1240) 38336AA260 3.18 (0.1252) 38336AA270 3.21 (0.1264) 38336AA280 3.24 (0.1276) 38336AA290 3.27 (0.1287) 38336AA300 3.30 (0.1299) 38336AA310 3.33 (0.1311) 38336AA320 3.36 (0.1323) 38336AA330 3.39 (0.1335) 38336AA340 3.42 (0.1346) 38336AA350 3.45 (0.1358) 38336AA360 3.48 (0.1370) 38336AA370 3.51 (0.1382) 38336AA380 3.54 (0.1394) 38336AA390 3.57 (0.1406) 38336AA400 3.60 (0.1417) 38336AA410 3.63 (0.1429) 38336AA420 3.66 (0.1441)
5. Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST. ST 18674AA000 INSTALLER
6. Insert the drive pinion into the differential carrier, and install the originally attached bearing preload adjusting spacer and washer.
7. Insert the spacer, then press-fit the pilot bearing with the ST. ST1 399780104 WEIGHT ST2 899580100 INSTALLER ST3 398507703 DUMMY COLLAR ST4 498937110 HOLDER DRIVE PINION
8. Press-fit the companion flange with ST1, ST2 and ST3. NOTE: Be careful not to damage the bearing. ST1 899874100 INSTALLER ST2 399780104 WEIGHT ST3 498937110 HOLDER DRIVE PINION
9. Install the self-locking nut. Tighten using the ST. ST 498427200 FLANGE WRENCH Tightening torque: 181.5 N.m (18.5 kgf-m, 134.0 ft-lb)
10. Turn the drive pinion shaft 10 or more times to make it fit in each taper roller bearing, and measure the initial load or initial torque. Initial load: 24.1 - 38.6 N (2.5 - 3.9 kgf, 5.4 - 8.71b) Initial torque: 0.91 - 7.46 N.m (0.09 - 0.15 kgf-m, 0.67-1.08 ft-lb)
11. If the bearing preload is outside the specification range, select a preload adjusting washer and spacer from the table below to fit within the specification range. PRELOAD ADJUSTING WASHER AND THICKNESS SPECIFICATION Preload adjusting washer Part No. Thickness mm (in) 383705200 2.59 (0.1020) 383715200 2.57 (0.1012) 383725200 2.55 (0.1004) 383735200 2.53 (0.0996) 383745200 2.51 (0.0988) 383755200 2.49 (0.0980) 383765200 2.47 (0.0972) 383775200 2.45 (0.0965) 383785200 2.43 (0.0957) 383795200 2.41 (0.0949) 383805200 2.39 (0.0941) 383815200 2.37 (0.0933) 383825200 2.35 (0.0925) 383835200 2.33 (0.0917) 383845200 2.31 (0.0909) PRELOAD ADJUSTING COLLAR AND THICKNESS SPECIFICATION Preload adjusting collar Part No. Thickness mm (in) 31454AA130 52.2 (2.055) 31454AA140 52.4 (2.063) 31454AA150 52.6 (2.071) 31454AA160 52.8 (2.079) 31454AA170 53.0 (2.087) 31454AA180 53.2 (2.094)
12. Remove the self-locking nut while holding the companion flange with ST. ST 498427200 FLANGE WRENCH
13. Draw out the companion flange with a puller.
14. Install a new oil seal using ST. NOTE: Press-fit until the oil seal end comes 1 mm (0.04 in) inward from end of carrier. Apply grease between the oil seal lips. ST 498447120 INSTALLER
15. Press-fit the companion flange with ST1, ST2 and ST3. ST1 899874100 INSTALLER ST2 399780104 WEIGHT ST3 498937110 HOLDER DRIVE PINION NOTE: Be careful not to damage the bearing.
16. Install the self-locking nut. Tighten using the ST. ST 498427200 FLANGE WRENCH
17. Check the initial torque and initial load. Initial load: 24.1 - 38.6 N (2.5 - 3.9 kgf, 5.4 - 8.71b) Initial torque: 0.91 - 1.46 N.m (0.09 - 0.15 kgf-m, 0.67- 1.08 ft-lb)
18. Install the driven gear to the differential case. NOTE: Before installing bolts, apply Lock Tite to bolt threads. Lock Tite: THREE BOND 1324 (Part No. 004403042) or equivalent NOTE: Tighten diagonally while gently tapping the bolt heads. Tightening torque: 103 N.m (10.5 kgf-m, 76 ft-lb)
19. Press the side bearing into differential case using ST. ST 398487700 DRIFT
20. Assembling the side retainer Using the ST and a press, press-fit the side bearing outer race. ST 398417700 DRIFT Install the oil seal. REPLACEMENT, Rear Differential Side Oil Seal .>
21. Adjusting the side bearing retainer shims The driven gear backlash and side bearing preload can be adjusted by the side bearing retainer shim thickness. Install the differential case assembly into differential carrier in the reverse order of disassembly. Install the side retainer shims and O-rings to retainers RH and LH from which they were removed. NOTE: Replace the broken or cracked O-ring with a new part. Replace broken or corroded side retainer shims with a new part of the same thickness. SIDE BEARING RETAINER SHIM AND THICKNESS SPECIFICATION Side bearing retainer shim Part No. Thickness mm (in) 383475201 0.20 (0.0079) 383475202 0.25 (0.0098) 383475203 0.30 (0.0118) 383475204 0.40 (0.0157) 383475205 0.50 (0.0197) Align the arrow mark on differential carrier with the mark on side retainer during installation. NOTE: Be careful that side bearing outer race is not damaged by the bearing roller. Tighten the side bearing retainer bolts. Tightening torque: 10.5 N.m (1.1 kgf-m, 7.7 ft-lb) Measure the driven gear to drive pinion backlash. Set the magnet base on the differential carrier. Align the contact point of dial gauge with the tooth surface of hypoid driven gear, and move the hypoid driven gear while securing the drive pinion. Read the value indicated on dial gauge. Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in) At the same time, measure the total preload of the drive pinion. Compared with the time when differential case is not installed, if the total preload is not within specification, adjust the thickness of side bearing retainer shims, increasing/reducing both shims by an even amount at a time. Total preload: 27.0 - 54.0 N (2.8 - 5.5 kgf, 6.1 - 12.2 lb)
22. Measure the driven gear to drive pinion backlash again. Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
23. Check the driven gear runout on its back surface, and make sure that the pinion and driven gear rotate smoothly. If the driven gear runout on its back surface exceeds the specification, check for any foreign objects between the hypoid driven gear and differential case, and for any deformation of the case or gear. Driven gear rear face runout limit: 0.05 mm (0.002 in)
24. Checking and adjusting the tooth contact of driven gear Apply an even coat of red lead on both sides of three or four teeth on the driven gear. Check the contact pattern after rotating the driven gear several revolutions back and forth until a definite contact pattern appears on the driven gear. If the contact pattern is improper, readjust it in accordance with the instruction in "Contact pattern". NOTE: Be sure to wipe off the red lead completely after the adjustment is completed. Correct tooth contact Check item: Tooth contact pattern is slightly shifted towards the toe side under no-load rotation. (When driving, it moves towards the heel side.) Face contact Check item: Backlash is too large. Contact pattern Corrective action: Increase the thickness of pinion height adjusting washer according to the procedure for bringing the drive pinion close to the driven gear. Flank contact Check item: Backlash is too small. Contact pattern Adjustment: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive the pinion away from driven gear. Toe contact (inner side contact) Check item: Contact area is too small. Contact pattern Adjustment: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive the pinion away from driven gear. Heel contact (outside end contact) Check item: Contact area is too small. Contact pattern Corrective action: Increase thickness of pinion height adjusting washer according to the procedures for moving the drive pinion closer to the driven gear.
25. If proper tooth contact is not obtained, once again adjust the drive pinion height by changing the RH and LH side bearing retainer shims and the hypoid gear backlash.
26. Install oil seals to side bearing retainers of both sides. REPLACEMENT, Rear Differential Side Oil Seal .>
27. Align the arrow mark on differential carrier with the mark on side retainer during installation.
28. Apply liquid gasket to the bolts indicated by the arrows, and tighten the side bearing retainer bolts. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Tightening torque: 10.5 N.m(1.1 kgf-m, 7.7 ft-lb)
29. Install the new gasket and rear cover, and tighten the bolts to the specified torque. Tightening torque: 44 N.m (4.5kgf-m, 32.5 ft-lb)
30. Install the breather cap.

SIDE GEAR BACKLASH

Using a dial gauge, check the backlash of side gear. (Model without LSD)

Side gear backlash

0.1 - 0.2 mm (0.004 - 0.008 in)

If the side gear backlash is not within the specification, select the side gear thrust washer and adjust the side gear backlash as specified.

Scheme 117

HYPOID DRIVEN GEAR BACKLASH

Using a dial gauge, check the backlash of hypoid driven gear.

Hypoid driven gear backlash

0.1 - 0.2 mm (0.004 - 0.008 in)

If the hypoid driven gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.

HYPOID DRIVEN GEAR RUNOUT ON ITS BACK SURFACE

Using a dial gauge, check the hypoid driven gear back surface runout.

Hypoid driven gear back surface runout

0.05 mm (0.002 in)

If the hypoid driven gear runout exceeds 0.05 mm (0.002 in), replace the hypoid driven gear.

TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION

Inspect the tooth contact between the hypoid driven gear and drive pinion. ASSEMBLY, Rear Differential (T-type) .>

TOTAL PRELOAD

Using a spring scale, check the total preload.

Total preload

Except for GT spec. B 6MT model

20.7 - 54.4 N (2.1 -5.5 kgf, 4.7 - 12.2 lb)

GT spec. B 6MT model

27.0 - 54.0 N (2.8 - 5.5 kgf, 6.1 - 12.2 lb)

If the total preload is not within the specification, adjust the side bearing retainer shims.

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Scheme 119

1. If rust or dirt is attached to the companion flange, remove them.
2. Set a dial gauge at a companion flange surface (mating surface of propeller shaft and companion flange), and then measure the companion flange runout. Limit of runout: 0.08 mm (0.003 in)
3. Set the gauge inside of the companion flange, and measure the runout. Limit of runout: 0.08 mm (0.003 in)
4. If either runout exceeds the limit, move the phase of companion flange and drive pinion 90° each, and find the point where the runout is within the limit.
5. If the runout exceeds the limit even after changing the phase, replace the companion flange and recheck the runout.
6. If the runout exceeds the limit after replacing the companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.

Adjust the side gear backlash.

ASSEMBLY, Rear Differential (T-type) .>

Adjust hypoid driven gear backlash.

ASSEMBLY, Rear Differential (T-type) .>

Adjust the tooth contact between hypoid driven gear and drive pinion gear.

ASSEMBLY, Rear Differential (T-type) .>

Adjust the side bearing shim.

ASSEMBLY, Rear Differential (T-type) .>

Scheme 120

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Scheme 122

1. Disconnect the ground cable from the battery.
2. Shift the select lever or gear shift lever to neutral.
3. Release the parking brake.
4. Lift the vehicle.
5. Remove the rear exhaust pipe and muffler.
6. Remove the heat shield cover.
7. Remove the propeller shaft. REMOVAL , Propeller Shaft .>
8. Prepare the transmission jack and band.
9. Loosen the self-lock nuts which hold the rear differential to rear crossmember.
10. Remove the DOJ of rear drive shaft from rear differential.
11. Remove the nuts which hold the rear differential front member.
12. Support the rear differential with the transmission jack.
13. Remove the rear differential front member.
14. Secure the rear differential using band.
15. Remove the self-lock nuts which hold the rear differential to rear crossmember.
16. Remove the rear differential stud bolt from rear crossmember bushing. NOTE: When removing the stud bolt, carefully adjust the angle and location of transmission jack and jack stand, if necessary.
17. Lower the transmission jack stand after removing the rear differential stud bolt from the rear crossmember. Rear drive shaft should not come into contact with the lateral link bolt.
18. Pull out the axle shaft from rear differential. NOTE: If it is difficult to remove the axle shaft from rear differential, remove it using tire lever.
19. Lower the transmission jack.
20. Secure the rear drive shaft to lateral link using wire.
21. Remove the rear differential member plate from rear differential.

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1. Insert the rear differential member plate into rear differential.
2. Set the rear differential to transmission jack. NOTE: Secure the rear differential to transmission jack using band.
3. Attach the ST to rear differential. ST 28099PA090 OIL SEAL PROTECTOR
4. Insert the spline shaft until the spline portion comes inside the side oil seal.
5. Remove ST from rear differential. ST 28099PA090 OIL SEAL PROTECTOR
6. Push the rear differential to insert the axle shaft into rear differential.
7. Adjust the transmission jack, if necessary, and insert the rear differential stud bolt into rear cross-member bushing properly.
8. After inserting the rear differential stud bolt into the rear crossmember bushing, lift up the transmission jack and align the rear differential to its attachment position.
9. Tighten a new self-locking nut temporarily to rear crossmember.
10. Remove the band from rear differential. Lift up the rear differential until the rear differential is separated from the transmission jack.
11. Install the rear differential front member with a new self-locking nut. Tightening torque: T1:50 N.m (5.1 kgf-m, 36.9 ft-lb) T2:110 N.m(11.2 kgf-m, 81 ft-lb)
12. Tighten the self-locking nut. Tightening torque: 70 N.m (7.1 kgf-m, 51 ft-lb)
13. Lower the transmission jack.
14. Install the propeller shaft. INSTALLATION , Propeller Shaft .>
15. Install the heat shield cover.
16. Install the rear exhaust pipe and muffler.

VA1-TYPE

To detect the real cause of trouble, inspect the following items before disassembling.

1. Tooth contact and backlash between hypoid driven gear and drive pinion
2. Hypoid driven gear runout on its back surface
3. Total preload of drive pinion

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1. Set the ST on vise and install the differential assembly to ST. ST 398217700 ATTACHMENT SET
2. Drain the gear oil by removing the plug.
3. Remove the mounting bolts, and remove the rear cover. NOTE: Remove it by tapping with a plastic hammer.
4. Remove the air breather cap. NOTE: Do not attempt to replace the air breather cap unless necessary. Whenever the air breather cap is removed, replace it with a new part.
5. Remove the lock plate RH and LH.
6. Remove the holder RH and LH with ST. ST 18630AA010 WRENCH COMPL RETAINER
7. Pull out the differential case assembly from differential carrier. NOTE: Be careful so that the teeth do not hit against the case.
8. Remove the bearing race from holder RH and LH with ST1 and ST2. ST1 499705401 PULLER ASSY ST2 499705404 SEAT
9. Remove the oil seal from holder RH and LH using screwdriver. NOTE: Perform this operation only when changing oil seal.
10. Extract the bearing cone with ST1 and ST2. NOTE: Do not attempt to disassemble the parts unless necessary. Set the puller so that its claws catch the edge of the bearing cone. Store so that the right and left side bearing races and cones are not mixed together. ST1 899524100 PULLER SET ST2 399520105 SEAT
11. Remove the hypoid driven gear by loosening hypoid driven gear bolts.
12. Drive out the pinion shaft lock pin from the hypoid driven gear side. NOTE: The lock pin is staked at the pin hole end on the differential case. Do not drive it out forcibly before removing the stake. ST 899904100 STRAIGHT PIN REMOVER
13. Draw out the pinion mate shaft and remove pinion mate gears, side gears and thrust washers. NOTE: The gears should be marked or kept separated right and left, and front and rear as well as thrust washers.
14. Remove the self-locking nut while holding the companion flange with ST. ST 498427200 FLANGE WRENCH
15. Extract the companion flange with a puller.
16. Press the end of drive pinion shaft and extract it together with rear bearing cone, pinion height adjusting washer and washer. NOTE: Hold the drive pinion so as not to drop it. ST 398467700 DRIFT
17. Remove the rear bearing cone from drive pinion by supporting the cone with ST. NOTE: Place the replacer so that its center-recessed side faces the pinion gear. ST 498515500 REPLACER
18. Remove the front oil seal from differential carrier using ST. ST 398527700 PULLER ASSY
19. Remove the pilot bearing together with the front bearing cone and collar using the ST. ST 398467700 DRIFT
20. When replacing the bearings, hit out the front bearing cup and rear bearing cup in this order using a brass bar.

VA2-TYPE

To detect the real cause of trouble, inspect the following items before disassembling.

1. Tooth contact and backlash between hypoid driven gear and drive pinion
2. Hypoid driven gear runout on its back surface
3. Total preload of drive pinion

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Scheme 156

1. Set the ST on vise and install the differential assembly to ST. ST 398217700 ATTACHMENT
2. Drain the gear oil by removing the plug.
3. Remove the mounting bolts, and remove the rear cover. NOTE: Remove it by tapping with a plastic hammer.
4. Remove the lock plate RH and LH.
5. Remove the holder RH and LH with ST. ST 18630AA010 WRENCH ASSY
6. Pull out the differential case assembly from differential carrier. NOTE: Be careful so that the teeth do not hit against the case.
7. Remove the bearing race from holder RH and LH with ST and press. ST 18758AA000 PULLER NOTE: Make sure the bolt of puller turn manually. Set the puller so that its claws catch the groove of holder.
8. Remove the oil seal from holder RH and LH using screwdriver. NOTE: Perform this operation only when changing oil seal.
9. Extract the bearing cone with ST1, ST2 and ST3 NOTE: Do not attempt to disassemble the parts unless necessary. Never mix up the RH and LH bearing races and cones. ST1 498077000 REMOVER ST2 399520105 SEAT ST3 899864100 REMOVER
10. Remove the hypoid driven gear by loosening hypoid driven gear bolts.
11. Remove the self-locking nut while holding the companion flange with ST. ST 498427200 FLANGE WRENCH
12. Extract the companion flange with a puller.
13. Removes the drive pinion shaft.
14. Remove the rear bearing cone from drive pinion by supporting the cone with ST. NOTE: Place the replacer so that its center-recessed side faces the pinion gear. ST 398517700 REPLACER
15. Remove the front oil seal from differential carrier using screwdriver.
16. Remove the pilot bearing, front bearing cone and collar.
17. When replacing the bearings, hit out the front bearing cup and rear bearing cup in this order using a brass bar.

Note. Assemble in the reverse order of disassembly. Check and adjust each part during assembly. Use a new gasket. Keep the shims and washers in order, so that they are not improperly installed. Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed. Apply gear oil when installing the bearings and thrust washers. Be careful not to mix up the RH and LH bearing races. Replace the oil seal with a new part at every disassembly. Apply grease to the lips when installing the oil seal. Be careful not to mix up the differential oil seal RH and LH.

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1. Adjusting preload for front and rear bearings Adjust the bearing preload between front and rear bearings with collar and washer. Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted. Install the rear bearing race into the differential carrier using ST1 and ST2. ST1 398477701 HANDLE ST2 398477702 DRIFT Install the front bearing race to the differential carrier using ST1 and ST2. ST1 398477701 HANDLE ST2 498447110 DRIFT Insert the front bearing cone. NOTE: Use new front bearing cone. Measure and record the thickness of the pinion height adjusting washer. NOTE: If tooth contact (drive pinion, hypoid driven gear) is normal in the inspection before disassembling, verify that the washer is not deformed, and then re-use the used washer. Insert ST1 into the case with the pinion height adjusting washer and rear bearing cone fitted onto it. NOTE: Use new rear bearing cone. Install the preload adjusting collar & washer, front bearing cone, ST2, companion flange, and washer & self-locking nut. ST 498447150 DUMMY SHAFT Part No. 32285AA000 Collar Turn the ST1 by hand to smooth the bearing, and tighten the self-locking nut while measuring the initial load or initial torque with a spring scale or torque wrench. Select the preload adjusting washer and collar so that the specified preload is obtained when nut is tightened to the specified torque. NOTE: Use a new self-locking nut. Measure the preload in direction of tangent to the flange. Be careful not to give excessive preload. When tightening the self-locking nut, lock ST1 with ST2 as shown in the figure. ST1 398507704 BLOCK ST2 498447150 DUMMY SHAFT Tightening torque: 191 N.m (19.5 kgf-m, 141.0 ft-lb) Initial load: 12.7 - 32.2 N (1.3 - 3.3 kgf, 2.9 - 7.2 lb) Initial torque: 0.48 - 1.22 N.m (0.05 - 0.12 kgf-m, 0.35 - 0.9 ft-lb) PRELOAD ADJUSTING WASHER AND THICKNESS SPECIFICATION Preload adjusting washer Part No. Thickness mm (in) 38336AA000 1.500 (0.0591) 38336AA120 1.513 (0.0596) 38336AA010 1.525 (0.0600) 38336AA130 1.538 (0.0606) 38336AA020 1.550 (0.0610) 38336AA140 1.563 (0.0615) 38336AA030 1.575 (0.0620) 38336AA150 1.588 (0.0625) 38336AA040 1.600 (0.0630) 38336AA160 1.613 (0.0635) 38336AA050 1.625 (0.0640) 38336AA170 1.638 (0.0645) 38336AA060 1.650 (0.0650) 38336AA180 1.663 (0.0655) 38336AA070 1.675 (0.0659) 38336AA190 1.688 (0.0665) 38336AA080 1.700 (0.0669) 38336AA200 1.713 (0.0674) 38336AA090 1.725 (0.0679) 38336AA210 1.738 (0.0684) 38336AA100 1.750 (0.0689) 38336AA220 1.763 (0.0694) 38336AA110 1.775 (0.0699) PRELOAD ADJUSTING COLLAR AND LENGTH SPECIFICATION Preload adjusting collar Part No. Length mm (in) 32288AA040 52.3 (2.059) 32288AA050 52.5 (2.067) 31454AA100 52.6 (2.071) 32288AA060 52.7 (2.075) 31454AA110 52.8 (2.079) 32288AA070 52.9 (2.083) 31454AA120 53.0 (2.087) 32288AA080 53.1 (2.091) 32288AA090 53.3 (2.098)
2. Adjusting drive pinion height: Adjust the drive pinion height with washer installed between the rear bearing cone and the back of pinion gear. Attach the ST2. ST1 498447150 DUMMY SHAFT ST2 498505501 DIFFERENTIAL CARRIER GAUGE Part No. 32285AA000 Collar Measure the clearance N between the end of ST2 and the end surface of ST1 by using a thickness gauge. NOTE: Make sure there is no clearance between the case and ST2. ST1 498447150 DUMMY SHAFT ST2 498505501 DIFFERENTIAL CARRIER GAUGE Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed washer with this one. NOTE: Adjust it using 1 - 3 washers. T = To + N - 0.05 (mm) PINION HEIGHT ADJUSTING WASHER AND THICKNESS SPECIFICATION T Thickness of pinion height adjusting washer mm (in) To Thickness of washer temporally inserted mm (in) N Clearance of thickness gauge mm (in) Memo: (Example of calculation) To = 0.15 mm N = 0.1 mm T = 0.15 + 0.1 - 0.05 = 0.2 mm Result: Thickness = 0.2 mm Therefore use part number 32295AA220. PINION HEIGHT ADJUSTING WASHER AND THICKNESS SPECIFICATION Pinion height adjusting washer Part No. Thickness mm (in) 32295AA200 0.150 (0.0059) 32295AA210 0.175 (0.0069) 32295AA220 0.200 (0.0079) 32295AA230 0.225 (0.0089) 32295AA240 0.250 (0.0098) 32295AA250 0.275 (0.0108)
3. Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST. ST 498175500 INSTALLER
4. Insert the drive pinion into the differential carrier, and install the preselected bearing preload adjusting collar and washer.
5. Press-fit the front bearing cone into the carrier with ST1, ST2 and collar. ST1 399780104 WEIGHT ST2 899580100 INSTALLER Part No. 32285AA000 Collar
6. Insert the collar, then press-fit the pilot bearing with ST1 and ST2. ST1 399780104 WEIGHT ST2 899580100 INSTALLER
7. Fit a new oil seal with ST. NOTE: Press-fit until the oil seal end comes 1 mm (0.04 in) inward from end of carrier. Apply grease to the oil seal lips. ST 498447120 INSTALLER
8. Press-fit the companion flange with ST1 and ST2. NOTE: Be careful not to damage the bearing. ST1 899874100 INSTALLER ST2 399780104 WEIGHT
9. Attach a new self-locking nut and secure the companion flange using ST, then tighten the nut. NOTE: Before installing lock nuts, apply seal material to lock nut threads. SEAL MATERIAL THREE BOND 1324 (Part No. 004403042) or equivalent ST 498427200 FLANGE WRENCH Tightening torque: 191 N-m (19.5 kgf-m, 141.0 ft-lb)
10. Check the initial torque and initial load. Initial load: 12.7 - 32.2 N (1.3 - 3.3 kgf, 2.9 - 7.2 lb) Initial torque: 0.48 - 1.22 N.m (0.05 - 0.12 kgf-m, 0.35 - 0.9 ft-lb)
11. Assembling differential case Install the side gears and pinion mate gears, with their thrust washers and pinion mate shaft, into the differential case. NOTE: Apply gear oil on both sides of the washer and on the side gear shaft before installing. Insert the pinion mate shaft into the differential case by aligning the lock pin holes. Measure the side gear backlash. Side gear backlash: 0.05 - 0.15 mm (0.002 - 0.006 in) Adjust the side gear backlash as specified by selecting side gear thrust washer. SIDE GEAR THRUST WASHER AND THICKNESS SPECIFICATION Side gear thrust washer Part No. Thickness mm (in) 803135011 0.925 - 0.950 (0.0364 - 0.0374) 803135012 0.950 - 0.975 (0.0374 - 0.0384) 803135013 0.975 - 1.000 (0.0384 - 0.0394) 803135014 1.000 - 1.025 (0.0394 - 0.0404) 803135015 1.025 - 1.050 (0.0404 - 0.0413) Check the condition of rotation after applying oil to the gear tooth surfaces and thrust surfaces. After inserting the pinion shaft lock pin into differential case, stake the both sides of the hole to prevent pin from falling off.
12. Install the hypoid driven gear to differential case. NOTE: Before installing bolts, apply seal material to bolt threads. SEAL MATERIAL THREE BOND 1324 (Part No. 004403042) or equivalent Tighten diagonally while tapping the bolt heads. Tightening torque: 62 N.m(6.3 kgf-m, 45.8 ft-lb)
13. Press the side bearing into differential case using ST. ST 498485400 DRIFT
14. Assemble holders. Install the oil seal into holder RH and LH. ST 498447100 INSTALLER Install the bearing race into holder RH and LH. ST 398477702 DRIFT CAUTION: Make sure that the RH and LH oil seals, bearing outer races and cones are properly assembled. Install the differential assembly into differential carrier in the reverse order of disassembly. NOTE: Be careful so that the teeth do not hit against the case. Temporally tighten the side holders RH and LH in differential carrier to install.
15. Perform the backlash adjustment between the hypoid driven gear and drive pinion, and preload adjustment of differential side bearing. Turn the drive pinion with ST for better fitting of differential side bearing. ST 498427200 FLANGE WRENCH Screw in the side holder LH until light contact is made with ST. ST 18630AA010 WRENCH COMPL RETAINER Back off the holder on the hypoid driven gear side by approx. 1 and 1/2 teeth, and tighten the other side holder by approx. 2 teeth [amount that the holder on hypoid driven gear side is turned back (1 and 1/2) + 1/2 teeth)]. [Back off amount of side (hypoid driven gear side) holder + 1/2 tooth.] This + 1/2 tooth gives preload. Temporarily tighten the lock plate. NOTE: Turn over the lock plate to shift the holder by 1/2 tooth. Measure the hypoid driven gear-to-drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of hypoid driven gear, and move hypoid driven gear while holding drive pinion still. Read the value indicated on dial gauge. NOTE: If measured value of backlash is not within the specified range, repeat the procedures for pinion driven gear set backlash adjustment and the differential side bearing preload adjustment. Backlash: 0.10 - 0.15 mm (0.004 - 0.006 in)
16. Put alignment marks on both the differential carrier and holder. Remove the holder side at a time. Replace them in the original position after inserting an O-ring and applying grease to the threaded portion.
17. Tighten the bolt of lock plate to specified torque. Tightening torque: 25 N.m (2.5 kgf-m, 18.5 ft-lb)
18. Recheck the hypoid driven gear to pinion backlash. Backlash: 0.10 - 0.15 mm (0.004 - 0.006 in)
19. Checking and adjusting the tooth contact of hypoid driven gear Apply an even coat of dye penatrant on both sides of three or four teeth on the hypoid driven gear. Check the contact pattern after rotating the hypoid driven gear several revolutions back and forth until a definite contact pattern appears on the hypoid driven gear. When the contact pattern is not correct, readjust. NOTE: Be sure to wipe off the dye penatrant completely after the adjustment is completed. Correct tooth contact Check item: Tooth contact pattern is slightly shifted towards the toe side under no-load rotation. (When driving, it moves towards the heel side.) Face contact Check item: Backlash is too large. Contact pattern Corrective action: Increase thickness of the pinion height adjusting washer according to the procedures for moving the drive pinion closer to the hypoid driven gear. Flank contact Check item: Backlash is too small. Contact pattern Corrective action: Reduce thickness of the pinion height adjusting washer according to the procedures for moving the drive pinion away from the hypoid driven gear. Toe contact (inner side contact) Check item: Contact area is too small. Contact pattern Corrective action: Reduce thickness of the pinion height adjusting washer according to the procedures for moving the drive pinion away from the hypoid driven gear. Heel contact (outside end contact) Check item: Contact area is too small. Contact pattern Corrective action: Increase thickness of the pinion height adjusting washer according to the procedures for moving the drive pinion closer to the hypoid driven gear.
20. If proper tooth contact is not obtained, once again adjust the drive pinion height and the differential side bearing preload (already mentioned) and the hypoid gear backlash.
21. Install the new gasket and rear cover to the differential carrier, and tighten the bolts to specified torque. Tightening torque: 25 N.m (2.5 kgf-m, 18.5 ft-lb)

Note. Assemble in the reverse order of disassembly. Check and adjust each part during assembly. Use a new gasket. Keep the shims and washers in order, so that they are not improperly installed. Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed. Apply gear oil when installing the bearings and thrust washers. Be careful not to mix up the RH and LH bearing races. Replace the oil seal with a new part at every disassembly. Apply grease to the lips when installing the oil seal. Be careful not to mix up the differential oil seal RH and LH.

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Scheme 187

Scheme 188

1. Adjusting preload for front and rear bearings Adjust the bearing preload between front and rear bearings with collar and washer. Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted. Install the rear bearing race into the differential carrier using ST1 and ST2. ST1 398477701 HANDLE ST2 398477703 DRIFT 2 Using the ST, install the front bearing race to the differential carrier. ST 499277200 INSTALLER Insert the front bearing cone. NOTE: Use new front bearing cone. Measure and record the thickness of the pinion adjusting washer. NOTE: If tooth contact (drive pinion, hypoid driven gear) is normal in the inspection before disassembling, verify that the washer is not deformed, and then re-use the used washer. Insert the ST1 into carrier with the pinion height adjusting washer and rear bearing cone fitted onto it. NOTE: Use new rear bearing cone. Install the preload adjusting collar & washer, front bearing cone, collar, companion flange, and washer & self-locking nut. ST1 18678AA000 DUMMY SHAFT Turn ST1 by hand to seat the bearing, and measure the initial load and initial torque with a spring scale or a torque wrench while tightening the selflocking nut. Select the preload adjusting washer and collar so that the specified preload is obtained when nut is tightened to the specified torque. NOTE: Use a new self-locking nut. Be careful not to give excessive preload. When tightening the self-locking nut, lock companion flange with ST2 as shown in the figure. Measure the preload in direction of tangent to the flange. ST1 18678AA000 DUMMY SHAFT ST2 498427200 FLANGE WRENCH Tightening torque: 191 N.m (19.5 kgf-m, 141.0 ft-lb) Initial load: 12.7 - 32.2 N (1.3 - 3.3 kgf, 2.9 - 7.2 lb) Initial torque: 0.48 - 1.22 N.m (0.05 - 0.12 kgf-m, 0.35 - 0.90 ft-lb) PRELOAD ADJUSTING WASHER AND THICKNESS SPECIFICATION Preload adjusting washer Part No. Thickness mm (in) 38336AA430 1.500 (0.0591) 38336AA440 1.513 (0.0596) 38336AA450 1.525 (0.0600) 38336AA460 1.538 (0.0606) 38336AA470 1.550 (0.0610) 38336AA480 1.563 (0.0615) 38336AA490 1.575 (0.0620) 38336AA500 1.588 (0.0625) 38336AA510 1.600 (0.0630) 38336AA520 1.613 (0.0635) 38336AA530 1.625 (0.0640) 38336AA540 1.638 (0.0645) 38336AA550 1.650 (0.0650) 38336AA560 1.663 (0.0655) 38336AA570 1.675 (0.0659) 38336AA580 1.688 (0.0665) 38336AA590 1.700 (0.0669) 38336AA600 1.713 (0.0674) 38336AA610 1.725 (0.0679) 38336AA620 1.738 (0.0684) 38336AA630 1.750 (0.0689) 38336AA640 1.763 (0.0694) 38336AA650 1.775 (0.0699) PRELOAD ADJUSTING COLLAR AND LENGTH SPECIFICATION Preload adjusting collar Part No. Length mm (in) 31454AA250 51.05 (2.010) 31454AA260 51.25 (2.018) 31454AA270 51.35 (2.022) 31454AA280 51.45 (2.026) 31454AA290 51.55 (2.030) 31454AA300 51.65 (2.033) 31454AA310 51.75 (2.037) 31454AA320 51.85 (2.041) 31454AA330 52.05 (2.049)
2. Adjusting drive pinion height: Adjust the drive pinion height with washer installed between the rear bearing cone and the back of pinion gear. Attach the ST2. ST1 18678AA000 DUMMY SHAFT ST2 18831AA010 DIFFERENTIAL CARRIER GAUGE Install the side holder LH to the left side of the differential carrier in reverse direction. Measure the clearance N between the end of ST2 and the end surface of ST1 by using a thickness gauge. NOTE: Make sure there is no clearance between the case and ST2. ST1 18678AA000 DUMMY SHAFT ST2 18831AA010 DIFFERENTIAL CARRIER GAUGE Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed washer with this one. NOTE: Adjust it using 1 - 3 washers. T = To + N - 0.05 (mm) PINION HEIGHT ADJUSTING WASHER AND THICKNESS SPECIFICATION T Thickness of pinion height adjusting washer mm (in) To Thickness of washer temporally inserted mm (in) N Clearance of thickness gauge mm (in) Memo: (Example of calculation) To = 0.15 mm N = 0.1 mm T = 0.15+ 0.1 -0.05 = 0.2 mm Result: Thickness = 0.2 mm Therefore use part number 32295AA370. PINION HEIGHT ADJUSTING WASHER AND THICKNESS SPECIFICATION Pinion height adjusting washer Part No. Thickness mm (in) 32295AA350 0.150 (0.0059) 32295AA360 0.175 (0.0069) 32295AA370 0.200 (0.0079) 32295AA380 0.225 (0.0089) 32295AA390 0.250 (0.0098) 32295AA400 0.275 (0.0108)
3. Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST. ST 398177700 INSTALLER
4. Insert the drive pinion into the differential carrier, and install the preselected bearing preload adjusting collar and washer.
5. Set ST and differential carrier to the press and install the front bearing cone. ST 399780104 WEIGHT NOTE: Set the carrier to the press until the companion flange is installed.
6. Insert the collar, then install the pilot bearing.
7. Fit a new oil seal with ST. NOTE: Press-fit until the oil seal end comes 1 mm (0.04 in) inward from end of carrier. Apply grease to the oil seal lips. ST 499277200 INSTALLER
8. Press-fit the companion flange with ST. NOTE: Be careful not to damage the bearing. ST 899874100 INSTALLER
9. Attach a new self-locking nut and secure the companion flange using ST, then tighten the nut. NOTE: Before installing lock nuts, apply seal material to lock nut threads. SEAL MATERIAL THREE BOND 1324 (Part No. 004403042) or equivalent ST 498427200 FLANGE WRENCH Tightening torque: 191 N.m (19.5 kgf-m, 141.0 ft-lb)
10. Measure the initial torque and initial load. Initial load: 12.7 - 32.2 N (1.3 - 3.3 kgf, 2.9 - 7.2 lb) Initial torque: 0.48 - 1.22 N.m (0.05 - 0.12 kgf-m, 0.35 - 0.90 ft-lb)
11. Install the hypoid driven gear to differential case. NOTE: Tighten diagonally while tapping the bolt heads. Set a cushioning such as wooden block, aluminum plate or shop cloth between vise and differential case if the side gear comes into contact with vise. Tightening torque: 62 N.m(6.3 kgf-m, 45.8 ft-lb)
12. Press the side bearing into differential case using ST. ST 398487700 DRIFT
13. Assemble holders. Install the new oil seal into holder RH and LH. ST 498447100 INSTALLER Install the bearing race into holder RH and LH. ST 398417700 DRIFT PUNCH CAUTION: Make sure that the RH and LH oil seals, bearing outer races and cones are properly assembled. Install the differential assembly into differential carrier in the reverse order of disassembly. NOTE: Be careful so that the teeth do not hit against the case. Temporally tighten the side holders RH and LH in differential carrier to install.
14. Perform the backlash adjustment between the hypoid driven gear and drive pinion, and preload adjustment of differential side bearing. Turn the drive pinion with ST for better fitting of differential side bearing. ST 498427200 FLANGE WRENCH Screw in the side holder LH until light contact is made with ST. ST 18630AA010 WRENCH COMPL RETAINER Back off the holder on the hypoid driven gear side by approx. 1 and 1/2 teeth, and tighten the other side holder by approx. 2 teeth [amount that the holder on hypoid driven gear side is turned back (1 and 1/2) + 1/2 teeth)]. [Back off amount of side (hypoid driven gear side) holder + 1/2 tooth.] This + 1/2 tooth gives preload. Temporarily tighten the lock plate. NOTE: Turn over the lock plate to shift the holder by 1/2 tooth. Measure the hypoid driven gear-to-drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of hypoid driven gear, and move hypoid driven gear while holding drive pinion still. Read the value indicated on dial gauge. NOTE: If measured value of backlash is not within the specified range, repeat the procedures for pinion driven gear set backlash adjustment and the differential side bearing preload adjustment. Backlash: 0.10 - 0.15 mm (0.004 - 0.006 in)
15. Put alignment marks on both the differential carrier and holder. Remove the holder side at a time. Replace them in the original position after inserting an O-ring and applying grease to the threaded portion.
16. Tighten the bolt of lock plate to specified torque. Tightening torque: 25 N.m (2.5 kgf-m, 18.5 ft-lb)
17. Recheck the hypoid driven gear to pinion backlash. Backlash: 0.10 - 0.15 mm (0.004 - 0.006 in)
18. Checking and adjusting the tooth contact of hypoid driven gear Apply an even coat of dye penatrant on both sides of three or four teeth on the hypoid driven gear. Check the contact pattern after rotating the hypoid driven gear several revolutions back and forth until a definite contact pattern appears on the hypoid driven gear. When the contact pattern is not correct, readjust. NOTE: Be sure to wipe off the dye penatrant completely after the adjustment is completed. Correct tooth contact Check item: Tooth contact pattern is slightly shifted towards the toe side under no-load rotation. (When driving, it moves towards the heel side.) Face contact Check item: Backlash is too large. Contact pattern Corrective action: Increase thickness of the pinion height adjusting washer according to the procedures for moving the drive pinion closer to the hypoid driven gear. Flank contact Check item: Backlash is too small. Contact pattern Corrective action: Reduce thickness of the pinion height adjusting washer according to the procedures for moving the drive pinion away from the hypoid driven gear. Toe contact (inner side contact) Check item: Contact area is too small. Contact pattern Corrective action: Reduce thickness of the pinion height adjusting washer according to the procedures for moving the drive pinion away from the hypoid driven gear. Heel contact (outside end contact) Check item: Contact area is too small. Contact pattern Corrective action: Increase thickness of the pinion height adjusting washer according to the procedures for moving the drive pinion closer to the hypoid driven gear.
19. If proper tooth contact is not obtained, once again adjust the drive pinion height and the differential side bearing preload (already mentioned) and the hypoid gear backlash.
20. Install the new gasket and rear cover to the differential carrier, and tighten the bolts to specified torque. Tightening torque: 25 N.m (2.5 kgf-m, 18.5 ft-lb)

Using a dial gauge, check the backlash of side gear. (VA1-type only)

Side gear backlash

0.05 - 0.15 mm (0.002 - 0.006 in)

If the side gear backlash is not within the specification, select the side gear thrust washer and adjust the side gear backlash as specified.

Using a dial gauge, check the backlash of hypoid driven gear.

Hypoid driven gear backlash

0.10 - 0.15 mm (0.004 - 0.006 in)

If the hypoid driven gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.

Inspect the tooth contact between the hypoid driven gear and drive pinion. ASSEMBLY, Rear Differential (VA-type) .>

COMPANION FLANGE

1. If rust or dirt is attached to the companion flange, remove them.
2. Set a dial gauge at a companion flange surface (mating surface of propeller shaft and companion flange), and then measure the companion flange runout. Limit of runout: 0.08 mm (0.003 in)
3. Set the gauge inside of the companion flange, and measure the runout. Limit of runout: 0.08 mm (0.003 in)
4. If either runout exceeds the limit, move the phase of companion flange and drive pinion 90° each, and find the point where the runout is within the limit.
5. If the runout exceeds the limit even after changing the phase, replace the companion flange and recheck the runout.
6. If the runout exceeds the limit after replacing the companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.

Adjust the side gear backlash. (VA1-type)

ASSEMBLY, Rear Differential (VA-type) .>

Adjust hypoid driven gear backlash.

ASSEMBLY, Rear Differential (VA-type) .>

Adjust the tooth contact between hypoid driven gear and drive pinion gear.

ASSEMBLY, Rear Differential (VA-type) .>