Differential: Other Suzuki Equator I

Precaution for Servicing Front Final Drive

1. Before starting diagnosis of the vehicle, understand the symptoms well. Perform correct and systematic operations.
2. Check for the correct installation status prior to removal or disassembly. When matching marks are required, be certain they do not interfere with the function of the parts they are applied to.
3. Overhaul should be done in a clean work area, a dust proof area is recommended.
4. Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from entering into the unit during disassembly or assembly.
5. Always use shop paper for cleaning the inside of components.
6. Avoid using cotton gloves or a shop cloth to prevent the entering of lint.
7. Check appearance of the disassembled parts for damage, deformation, and abnormal wear. Replace them with new ones if necessary.
8. Gaskets, seals and O-rings should be replaced any time the unit is disassembled.
9. Clean and flush the parts sufficiently and blow them dry.
10. Be careful not to damage sliding surfaces and mating surfaces.
11. When applying sealant, remove the old sealant from the mating surface; then remove any moisture, oil, and foreign materials from the application and mating surfaces.
12. In principle, tighten nuts or bolts gradually in several steps working diagonally from inside to outside. If a tightening sequence is specified, observe it.
13. During assembly, observe the specified tightening torque.
14. Add new differential gear oil, petroleum jelly, or multi-purpose grease, as specified.

Scheme 159

Drive Pinion and Drive Gear

1. If the drive pinion and drive gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or replace as necessary.
2. If the drive pinion or drive gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new drive pinion and drive gear.
3. Drive pinion and drive gear are supplied in matched sets only. Matching numbers on both drive pinion and drive gear are etched for verification. If a new drive pinion and drive gear set are being used, verify the numbers of each drive pinion and drive gear before proceeding with assembly.

Bearing

1. If bearings are chipped (by friction), pitted, worn, rusted, scratched, or unusual noise is coming from bearing, replace with new bearing assembly (as a new set).
2. Bearing must be replaced with a new one whenever disassembled.

Side Gear and Pinion Mate Gear

1. If any cracks or damage are found on the surface of the teeth, replace with new one.
2. If any worn or chipped marks are found on the side of the side gear and pinion mate gear which contact the thrust washer, replace with new one.
3. Replace both side gear and pinion mate gear as a set when replacing side gear or pinion mate gear.

Side Gear Thrust Washer and Pinion Mate Thrust Washer

1. If any chips (by friction), damage, or unusual wear are found, replace with new one.

Gear Carrier

1. If any wear or cracks are found on the contact sides of gear carrier, replace with new one.

Companion Flange

1. If any chips (about 0.1 mm, 0.004 in) or other damage on the companion flange surface which contacts the front oil seal lips are found, replace with new one.

Side Gear Back Clearance

1. Assemble the differential parts if they are disassembled. Refer to [ «FRONT FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S21000174652010102800000) ].

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1. Place the differential case straight up so that the side gear to be measured is upward.
2. Using feeler gauges, measure the clearance between the side gear back and differential case at three different points, while rotating the side gear. Average the three readings to calculate the clearance. (Measure the clearance of the other side as well.) Side gear back clearance: 0.1 mm (0.004 in) or less. If the side gear back clearance is outside of the specification, use a thicker or thinner side gear thrust washer to adjust. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S32633910822010102800000) ]. If the side gear back clearance is greater than specification: Use a thicker side gear thrust washer. If the side gear back clearance is less than specification: Use a thinner side gear thrust washer. CAUTION: Insert feeler gauges with the same thickness on both sides to prevent side gear from tilting. Each gear should rotate smoothly without excessive resistance during differential motion. Select a side gear thrust washer for right and left individually. NOTE: Side gear back clearance is clearance between side gear and differential case for adjusting side gear backlash.

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1. Make sure all parts are clean and that the bearings are well lubricated.
2. Assemble the drive pinion bearings onto the Tool. Tool number: - (J-34309) Drive pinion front bearing; make sure the J-34309-3 drive pinion front bearing seat is secured tightly against the J-34309-2 gauge anvil. Then turn the J-34309-7 drive pinion front bearing pilot to secure the drive pinon front bearing in its proper position. Drive pinion rear bearing; the J-34309-8 drive pinion rear bearing pilot is used to center the drive pinion rear bearing only. The J-34309-4 drive pinion rear bearing locking seat is used to lock the drive pinion rear bearing to the assembly. Installation of J-34309-9 and J-34309-16; place a suitable 2.5 mm (0.098 in) thick plain washer between J-34309-9 and J-34309-16. Both surfaces of J-34309-9 and J-34309- 16 must be parallel with a clearance of 2.5 mm (0.098 in).
3. Install the drive pinion rear bearing inner race into the gear carrier. Then insert the drive pinion height adjusting washer selector tool, J-34309-1, gauge screw assembly.
4. Assemble the drive pinion front bearing inner race and the J-34309-2 gauge anvil. Assemble them together with the J-34309-1 gauge screw in the gear carrier. Make sure that the drive pinion height gauge plate, J-34309-16, will turn a full 360°. Tighten the two sections together by hand.
5. Turn the assembly several times to seat the drive pinon bearings.
6. Measure the turning torque at the end of the J-34309-2 gauge anvil using Tool. Tool number: ST3127S000 (J-25765-A) Turning torque specification: 1.0 - 1.6 N.m (0.11 - 0.16 kg-m, 9 - 14 in-lb)
7. Place the J-34309-10 "R180A" drive pinion height adapter onto the gauge plate and tighten it by hand. CAUTION: Make sure all machined surfaces are clean.
8. Position the side bearing discs, Tool, and arbor firmly into the side bearing bores. Install the side bearing caps and tighten the side bearing cap bolts to the specified torque. Refer to [ «FRONT FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S21000174652010102800000) ]. Tool number: - (J-25269-18)
9. Select the correct standard drive pinion height adjusting washer thickness. Select by using a standard gauge of 3 mm (0.12 in) and your J-34309-101 feeler gauge. Measure the distance between the J-34309-10 drive pinion height adapter, including the standard gauge and the arbor.
10. Write down the exact measurement (the value of feeler gauge).
11. Correct the drive pinion height adjusting washer size by referring to the drive pinion "head number". There are two numbers painted on the drive pinion. The first one refers to the drive pinion and drive gear as a matched set. This number should be the same as the number on the drive gear. The second number is the drive pinion "head number". It refers to the ideal drive pinion height from standard for quietest operation. Use the following chart to determine the correct drive pinion height adjusting washer. WASHER THICKNESS CHART Head number Add or remove from the standard drive pinion height adjusting washer thickness measurement -6 Add 0.06 mm (0.0024 in) -5 Add 0.05 mm (0.0020 in) -4 Add 0.04 mm (0.0016 in) -3 Add 0.03 mm (0.0012 in) -2 Add 0.02 mm (0.0008 in) -1 Add 0.01 mm (0.0004 in) 0 Use the selected washer thickness +1 Subtract 0.01 mm (0.0004 in) +2 Subtract 0.02 mm (0.0008 in) +3 Subtract 0.03 mm (0.0012 in) +4 Subtract 0.04 mm (0.0016 in) +5 Subtract 0.05 mm (0.0020 in) +6 Subtract 0.06 mm (0.0024 in)
12. Select the correct drive pinion height adjusting washer. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S32633910822010102800000) ].
13. Remove the Tool from the gear carrier and disassemble to retrieve the drive pinion bearings. Tool number: - (J-34309)

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1. Install drive pinion rear bearing outer race and drive pinion front bearing outer race using Tools. Tool number A: ST30611000 (J-25742- 1) B: ST30613000 (J-25742- 3) C: KV38100200 (J-26233) CAUTION: First tap the drive pinion bearing outer race until it becomes flush with the gear carrier. Do not reuse drive pinion front and rear bearing outer race.
2. Select drive pinion height adjusting washer. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S32633910822010102800000) ].
3. Install the selected drive pinion height adjusting washer to the drive pinion. Press the drive pinion rear bearing inner race to it using Tool. Tool number: ST30901000 (J-26010-01) CAUTION: Install the drive pinion height adjusting washer in the proper direction as shown. Do not reuse drive pinion rear bearing inner race.
4. Install the collapsible spacer to the drive pinion. CAUTION: Do not reuse collapsible spacer.
5. Apply differential gear oil to the drive pinion rear bearing, and install the drive pinion assembly to the gear carrier.
6. Apply differential gear oil to the drive pinion front bearing, and install the drive pinion front bearing inner race to the drive pinion assembly. CAUTION: Do not reuse drive pinion front bearing inner race.
7. Press the drive pinion front bearing inner race to the drive pinion as far as drive pinion lock nut can be tightened using Tool. Tool number: ST33200000 (J-26082)
8. Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new front oil seal. Then drive the new front oil seal in evenly until it becomes flush with the gear carrier using Tools. Tool number A: ST30720000 (J-25405) B: ST27863000 ( - ) CAUTION: Do not reuse front oil seal. Do not incline the new front oil seal when installing. Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new front oil seal.
9. Install the companion flange to the drive pinion while aligning the matching marks.
10. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut. Then adjust the drive pinion lock nut tightening torque using Tool A, and check the drive pinion bearing preload torque using Tool B. Tool number A: KV38108300 (J-44195) B: ST3127S000 (J-25765-A) Drive pinion bearing preload torque: 1.08 - 1.66 N.m (0.11 - 0.16 kg-m, 10 - 14 in-lb) CAUTION: Do not reuse drive pinion lock nut. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut. Adjust the drive pinion lock nut tightening torque to the lower limit first. Do not exceed the drive pinion lock nut specified torque. Refer to [ «FRONT FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S21000174652010102800000) ]. If the drive pinion bearing preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Do not loosen drive pinion lock nut to adjust the drive pinion bearing preload torque. After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.
11. Check companion flange runout. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S32633910822010102800000) ].
12. Install the differential case assembly. Refer to [ «FRONT FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S21000174652010102800000) ].

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1. Install side gear thrust washers with the same thickness as the ones installed prior to disassembly, or reinstall the old ones on the side gears.
2. Install the side gears and side gear thrust washers into the differential case.
3. Install the pinion mate thrust washers to the two pinion mate gears. Then install the pinion mate gears with the pinion mate thrust washers by aligning them in diagonally opposite positions and rotating them into the differential case.
4. Install the pinion mate shaft and align the lock pin hole on the pinion mate shaft with the lock pin hole on the differential case.
5. Measure the side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S32633910822010102800000) ].
6. Drive a new lock pin into the pinion mate shaft until it is flush with the differential case using suitable tool. CAUTION: Do not reuse lock pin.
7. Align the matching mark of the differential case with the mark of the drive gear, then place the drive gear onto the differential case.
8. Apply thread locking sealant into the threaded holes of the drive gear and install the new drive gear bolts. Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ] CAUTION: Make sure the drive gear back and threaded holes are clean.
9. Tighten the new drive gear bolts to the specified torque. Refer to [ «FRONT FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S21000174652010102800000) ]. After tightening the new drive gear bolts to the specified torque, tighten an additional 34° to 39° using Tool (A). Tool number: KV10112100-A (BT-8653-A) CAUTION: Always use Tool. Avoid tightening based on visual check alone. Tighten new drive gear bolts in a crisscross pattern.
10. Press the new side bearing inner races to the differential case using Tools. Tool number A: ST33230000 (J-35867) B: ST33061000 (J-8107-2) CAUTION: Do not reuse side bearing inner races.
11. Install housing spacer into gear carrier.
12. Apply differential gear oil to the side bearings, and install the differential case assembly with the side bearing outer races into the gear carrier. CAUTION: Do not reuse side bearing outer race when replacing side bearing inner race (replace as a set).
13. Insert left and right original side bearing adjusting washers in place between side bearings and gear carrier using Tool. Tool number: KV38100600 (J-25267)
14. Install the side bearing caps with the matching marks aligned and tighten the side bearing cap bolts to the specified torque. Refer to [ «FRONT FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S21000174652010102800000) ].
15. Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new side oil seal. Then drive the new side oil seal in evenly until it becomes flush with the gear carrier using Tools. Tool number A: ST30720000 (J-25405) B: ST27863000 ( - ) CAUTION: Do not reuse side oil seal. Do not incline the new side oil seal when installing. Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new side oil seal.
16. Check and adjust tooth contact, backlash, drive gear runout and total preload torque. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S32633910822010102800000) ]. Recheck above items.
17. Apply a 3 mm (0.12 in) bead of sealant to the mating surface of the carrier cover as shown. Use Genuine Silicone RTV or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ] CAUTION: Remove any old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to the application and mating surfaces.
18. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Refer to [ «FRONT FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S21000174652010102800000) ].

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1. Press differential side shaft bearing to differential side shaft. CAUTION: Do not reuse differential side shaft bearing.
2. Install snap ring (differential side shaft side).
3. Install differential side shaft assembly into gear carrier.
4. Install snap ring (hole side).
5. Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new side oil seal. Then drive the new side oil seal in evenly until it becomes flush with the gear carrier using Tools. Tool number A: ST30720000 (J-25405) B: ST27863000 ( - ) CAUTION: Do not reuse side oil seal. Do not incline the new side oil seal when installing. Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new side oil seal.

DRIVE GEAR RUNOUT

DRIVE GEAR RUNOUT CHART

SIDE GEAR CLEARANCE

ITEM SPECIFICATION

BACKLASH

ITEM SPECIFICATION

COMPANION FLANGE RUNOUT

COMPANION FLANGE RUNOUT CHART

SELECTIVE PARTS

Drive Pinion Height Adjusting Washer

PART THICKNESS CHART

Side Gear Thrust Washer

SIDE GEAR THRUST WASHER THICKNESS CHART

Side Bearing Adjusting Washer

SIDE BEARING ADJUSTING WASHER THICKNESS CHART

Special Service Tool

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

SPECIAL SERVICE TOOL REFERENCE Tool number (Kent-Moore No.) Tool name Description KV38108300 (J-44195) Flange wrench Removing and installing drive pinion lock nut KV381054S0 (J-34286) Puller Removing front oil seal ST30720000 (J-25405) Drift Installing front oil seal Installing side oil seal 77 mm (3.03 in) dia. 55.5 mm (2.185 in) dia. ST27863000 ( - ) Drift Installing front oil seal Installing side oil seal 74.5 mm (2.933 in) dia. 62.5 mm (2.461 in) dia. ST3127S000 (J-25765-A) Preload gauge GG91030000 (J-25765) Torque wrench HT62940000 ( - ) Socket adapter (1/2") HT62900000 ( - ) Socket adapter (3/8") Measuring drive pinion bearing preload torque and total preload torque KV10111100 (J-37228) Seal cutter Removing carrier cover ST3306S001 ( - ) Differential side bearing puller set ST33051001 (J-22888-20) Puller ST33061000 (J-8107-2) Base Removing and installing side bearing inner race 28.5 mm (1.122 in) dia. 38 mm (1.50 in) dia. ST30031000 (J-22912-01) Replacer Removing drive pinion rear bearing inner race KV38100600 (J-25267) Drift Installing side bearing adjusting washer ST30613000 (J-25742-3) Drift Installing drive pinion rear bearing outer race 72 mm (2.83 in) dia. 48 mm (1.89 in) dia. ST30611000 (J-25742-1) Drift bar Installing drive pinion rear bearing outer race (Use with ST30613000) KV38100200 (J-26233) Drift Installing drive pinion front bearing outer race 65 mm (2.56 in) dia. 49 mm (1.93 in) dia. ST30901000 (J-26010-01) Drift Installing drive pinion rear bearing inner race 79 mm (3.11 in) dia. 45 mm (1.77 in) dia. 35.2 mm (1.386 in) dia. ST33200000 (J-26082) Drift Installing drive pinion front bearing inner race 60 mm (2.36 in) dia. 44.5 mm (1.752 in) dia. ST33230000 (J-35867) Drift Installing side bearing inner race 51 mm (2.01 in) dia. 41 mm (1.61 in) dia. 28 mm (1.10 in) dia. ( - ) (J-34309) Differential shim selector tool Adjusting bearing preload and drive pinion height ( - ) (J-25269-18) Side bearing disc (2 Req'd) Selecting drive pinion height adjusting washer KV10112100 (BT-8653-A) Angle wrench Tightening bolts for drive gear

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Commercial Service Tool

COMMERCIAL SERVICE TOOL REFERENCE Tool name Description Power tool Loosening nuts and bolts

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Precaution for Servicing Rear Final Drive

1. Before starting diagnosis of the vehicle, understand the symptoms well. Perform correct and systematic operations.
2. Check for the correct installation status prior to removal or disassembly. When matching marks are required, be certain they do not interfere with the function of the parts they are applied to.
3. Overhaul should be done in a clean work area, a dust proof area is recommended.
4. Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from entering into the unit during disassembly or assembly.
5. Always use shop paper for cleaning the inside of components.
6. Avoid using cotton gloves or a shop cloth to prevent the entering of lint.
7. Check appearance of the disassembled parts for damage, deformation, and abnormal wear. Replace them with new ones if necessary.
8. Gaskets, seals and O-rings should be replaced any time the unit is disassembled.
9. Clean and flush the parts sufficiently and blow them dry.
10. Be careful not to damage sliding surfaces and mating surfaces.
11. When applying sealant, remove the old sealant from the mating surface; then remove any moisture, oil, and foreign materials from the application and mating surfaces.
12. In principle, tighten nuts or bolts gradually in several steps working diagonally from inside to outside. If a tightening sequence is specified, observe it.
13. During assembly, observe the specified tightening torque.
14. Add new differential gear oil, petroleum jelly, or multi-purpose grease, as specified.

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Tooth Contact

Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive pinion. Gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check gear tooth contact pattern to obtain the best contact for low noise and long life.

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1. Apply red lead to drive gear. NOTE: Apply red lead to both faces of three to four gears, at four locations evenly spaced on the drive gear.
2. Rotate the drive gear back and forth several times. Then check for correct drive pinion to drive gear tooth contact as shown. CAUTION: Check tooth contact on drive side and reverse side.
3. If the tooth contact is improperly adjusted, follow the procedure below to adjust the pinion height (dimension X). If the tooth contact is near the face (face contact), or near the heel (heel contact), use a thicker drive pinion height adjusting washers to move the drive pinion closer to the drive gear. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S18481676992010102800000) ]. If the tooth contact is near the flank (flank contact), or near the toe (toe contact), use a thinner drive pinion height adjusting washers to move the drive pinion farther from the drive gear. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S18481676992010102800000) ].

Scheme 219

1. Fit a dial indicator to the drive gear face to measure the backlash. Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in) If the backlash is outside of the specification, change the thickness of each side bearing adjusting washer. If the backlash is greater than specification: Make drive gear back side adjusting washer thicker, and drive gear tooth side adjusting washer thinner by the same amount. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S18481676992010102800000) ]. If the backlash is less than specification: Make drive gear back side adjusting washer thinner, and drive gear tooth side adjusting washer thicker by the same amount. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S18481676992010102800000) ]. CAUTION: Do not change the total thickness of side bearing adjusting washers as it will change the side bearing preload torque.

Scheme 220

1. Rotate companion flange and check for runout on the companion flange face (inner side of the bolt holes) and companion flange inner side (socket diameter) using suitable tool. Runout limit: 0.08 mm (0.0031 in) or less
2. If the runout is outside the runout limit, follow the procedure below to adjust. Rotate the companion flange on the drive pinion by 90°, 180° and 270° while checking for the position where the runout is minimum. If the runout is still outside of the runout limit after the companion flange has been rotated on the drive pinion, possible cause could be an assembly malfunction of drive pinion and drive pinion bearing or a malfunctioning drive pinion bearing. If the runout is still outside of the runout limit after repair of the assembly of drive pinion and drive pinion bearing or drive pinion bearing, replace the companion flange.

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1. Remove carrier cover bolts.
2. Remove carrier cover using Tool. Tool number: KV10111100 (J-37228) CAUTION: Do not damage the mating surface. Do not insert flat-bladed screwdriver, this will damage the mating surface.
3. For proper reinstallation, paint matching marks on one side of side bearing cap. CAUTION: Side bearing caps are line-board for initial assembly. The matching marks are used to reinstall them in their original positions. For matching mark, use paint. Do not damage side bearing cap.
4. Remove side bearing caps.
5. Remove differential case assembly using suitable tool. Keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusting washers together with bearings.
6. Remove side bearing inner race using Tools. Tool number A: ST33051001 (J-22888-20) B: ST33061000 (J-8107-2) CAUTION: Engage puller jaws in groove to prevent damage. To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise. It is not necessary to remove side bearing inner race except if it is replaced.
7. For proper reinstallation, paint matching mark on one differential case assembly. CAUTION: Use paint for matching marks. Do not damage differential case or drive gear.
8. Remove drive gear bolts.
9. Tap the drive gear off the differential case assembly using suitable tool. CAUTION: Tap evenly all around to keep drive gear from binding.
10. Remove the lock pin of pinion mate shaft from the drive gear side using suitable tool.
11. Remove pinion mate shaft.
12. Turn the pinion mate gear, then remove the pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from differential case.

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1. Remove differential case assembly. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ].
2. Remove drive pinion lock nut using Tool. Tool number: KV38108300 ( - )
3. Put matching marks on the companion flange and drive pinion using paint. CAUTION: Use paint to make the matching marks. Do not damage the companion flange or drive pinion.
4. Remove companion flange using suitable Tool.
5. Remove drive pinion assembly from gear carrier using suitable tool. CAUTION: Do not drop drive pinion assembly.
6. Remove front oil seal.
7. Remove drive pinion front bearing inner race.
8. Remove collapsible spacer.
9. Remove drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool. Tool number: ST30031000 (J-22912-01)
10. Tap drive pinion front and rear bearing outer races uniformly with a brass bar or equivalent to remove. CAUTION: Do not damage gear carrier.

1. If the drive pinion and drive gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or replace as necessary.
2. If the drive pinion or drive gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new drive pinion and drive gear.
3. Drive pinion and drive gear are supplied in matched sets only. Matching numbers on both drive pinion and drive gear are etched for verification. If a new drive pinion and drive gear set are being used, verify the numbers of each drive pinion and drive gear before proceeding with assembly.

1. If bearings are chipped (by friction), pitted, worn, rusted, scratched, or unusual noise is coming from bearing, replace with new bearing assembly (as a new set).
2. Bearing must be replaced with a new one whenever disassembled.

1. If any cracks or damage are found on the surface of the teeth, replace with new one.
2. If any worn or chipped marks are found on the side of the side gear and pinion mate gear which contact the thrust washer, replace with new one.
3. Replace both side gear and pinion mate gear as a set when replacing side gear or pinion mate gear.

1. If any chips (by friction), damage, or unusual wear are found, replace with new one.

1. If any wear or cracks are found on the contact sides of gear carrier, replace with new one.

1. If any chips (about 0.1mm, 0.004 in) or other damage on the companion flange surface which contacts the front oil seal lips are found, replace with new one.

1. Assemble the differential parts if they are disassembled. Refer to " «DIFFERENTIAL ASSEMBLY»(ref-375708-S40956487362010102800000) ".

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1. Place the differential case straight up so that the side gear to be measured is upward.
2. Using feeler gauges, measure the clearance between the side gear back and differential case at three different points, while rotating the side gear. Average the three readings to calculate the clearance. (Measure the clearance of the other side as well.) Side gear back clearance: 0.1 - 0.2 mm (0.004 - 0.008 in) or less. If the side gear back clearance is outside of the specification, use a thicker or thinner side gear thrust washer to adjust. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ]. If the side gear back clearance is greater than specification: Use a thicker side gear thrust washer. If the side gear back clearance is less than specification: Use a thinner side gear thrust washer. CAUTION: Insert feeler gauges with the same thickness on both sides to prevent side gear from tilting. Each gear should rotate smoothly without excessive resistance during differential motion. Select a side gear thrust washer for right and left individually. NOTE: Side gear back clearance is clearance between side gear and differential case for adjusting side gear backlash.

2WD MODELS

GENERAL SPECIFICATION

4WD MODELS

GENERAL SPECIFICATION

DRIVE GEAR RUNOUT CHART

SIDE GEAR CLEARANCE

ITEM SPECIFICATION

COMPANION FLANGE RUNOUT CHART

Side Gear Thrust Washer

SIDE GEAR THRUST WASHER CHART

Drive Pinion Height Adjusting Washer

DRIVE PINION HEIGHT ADJUSTING WASHER THICKNESS CHART

Side Bearing Adjusting Washer

SIDE BEARING ADJUSTING WASHER THICKNESS CHART

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

SPECIAL TOOLS AND EQUIPMENT CHART Tool number (Kent-Moore No.) Tool name Description KV38108300 ( - ) Flange wrench Removing and installing drive pinion lock nut KV38100500 (J-25273) Drift Installing front oil seal 80 mm (3.15 in) dia. 60 mm (2.36 in) dia. ST3127S000 (J-25765-A) Preload gauge GG91030000 (J-25765) Torque wrench HT62940000 ( - ) Socket adapter (1/2") HT62900000 ( - ) Socket adapter (3/8") Measuring drive pinion bearing preload torque and total preload torque KV10111100 (J-37228) Seal cutter Removing carrier cover ST3306S001 ( - ) Differential side bearing puller set ST33051001 (J-22888-20) Puller ST33061000 (J-8107-2) Base Removing and installing side bearing inner race 28.5 mm (1.122 in) dia. 38 mm (1.50 in) dia. ST30031000 (J-22912-01) Puller Removing drive pinion rear bearing inner race KV38100600 (J-25267) Drift Installing side bearing adjusting washer 8 mm (0.31 in) R42.5 mm (1.673 in) ST30621000 (J-25742-5) Drift Installing drive pinion rear bearing outer race 79 mm (3.11 in) dia. 59 mm (2.32 in) dia. ST30613000 (J-25742-3) Drift Installing drive pinion front bearing outer race 72 mm (2.83 in) dia. 48 mm (1.89 in) dia. ST30611000 (J-25742-1) Drift bar Installing drive pinion front bearing outer race [Use with ST30613000 (J-25742-3) and ST30621000 (J-25742-5)] ST30901000 (J-26010-01) Drift Installing drive pinion rear bearing inner race 79 mm (3.11 in) dia. 45 mm (1.77 in) dia. 35.2 mm (1.386 in) dia. ST3323 0000 (J-25805-01) Drift Installing side bearing inner race 51 mm (2.01 in) dia. 41 mm (1.61 in) dia. 28.5 mm (1.122 in) dia. - (J-8129) Spring gauge Measuring turning torque - (J-34309) Differential shim selector tool Adjusting bearing preload and pinion gear height - (J-25269-4) Side bearing disc (2 Req'd) Selecting pinion height adjusting washer

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COMMERCIAL SERVICE TOOL REFERENCE Tool name Description Spacer Installing pinion front bearing inner race 60 mm (2.36 in) dia. 36 mm (1.42 in) dia. 30 mm (1.18 in) Power tool Loosening nuts and bolts

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1. Before starting diagnosis of the vehicle, understand the symptoms well. Perform correct and systematic operations.
2. Check for the correct installation status prior to removal or disassembly. When matching marks are required, be certain they do not interfere with the function of the parts they are applied to.
3. Overhaul should be done in a clean work area, a dust proof area is recommended.
4. Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from entering into the unit during disassembly or assembly.
5. Always use shop paper for cleaning the inside of components.
6. Avoid using cotton gloves or a shop cloth to prevent the entering of lint.
7. Check appearance of the disassembled parts for damage, deformation, and abnormal wear. Replace them with new ones if necessary.
8. Gaskets, seals and O-rings should be replaced any time the unit is disassembled.
9. Clean and flush the parts sufficiently and blow them dry.
10. Be careful not to damage sliding surfaces and mating surfaces.
11. When applying sealant, remove the old sealant from the mating surface; then remove any moisture, oil, and foreign materials from the application and mating surfaces.
12. In principle, tighten nuts or bolts gradually in several steps working diagonally from inside to outside. If a tightening sequence is specified, observe it.
13. During assembly, observe the specified tightening torque.
14. Add new differential gear oil, petroleum jelly, or multi-purpose grease, as specified.

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Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive pinion. Gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check gear tooth contact pattern to obtain the best contact for low noise and long life.

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1. Thoroughly clean drive gear and drive pinion teeth.
2. Apply red lead to drive gear. NOTE: Apply red lead to both faces of three to four gears, at four locations evenly spaced on the drive gear.
3. Hold companion flange steady by hand and rotate drive gear in both directions.
4. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer to [ «REAR FINAL DRIVE ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375708-S02261239832010102800000) ] and [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S33102195872010102800000) ].

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1. Fit a dial indicator to the drive gear face to measure the backlash. Backlash: 0.08 - 0.13 mm (0.0031 - 0.0051 in)
2. If the backlash is outside of the specification, adjust each side bearing side bearing adjuster. Remove adjuster lock plate. Loosen side bearing cap bolts. Tighten or loosen each side bearing adjuster using Tool. Tool number: - (C - 4164) If the backlash is greater than specification: Loosen side bearing adjuster A and tighten side bearing adjuster B by the same amount. If the backlash is less than specification: Loosen side bearing adjuster B and tighten side bearing adjuster A by the same amount. CAUTION: Do not change the side bearing side bearing adjusters by different amounts as it will change the side bearing preload torque. Tighten side bearing cap bolts to the specified torque. Refer to [ «REAR FINAL DRIVE ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375708-S02261239832010102800000) ]. Install adjuster lock plate and tighten to the specified torque. Refer to [ «REAR FINAL DRIVE ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375708-S02261239832010102800000) ]. CAUTION: Check tooth contact and total preload torque after adjusting side bearing adjuster. Refer to " «TOOTH CONTACT»(ref-375708-S17776813392010102800000) " and " «TOTAL PRELOAD TORQUE»(ref-375708-S16894277472010102800000) ".

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1. Rotate companion flange and check for runout on the companion flange face (inner side of the bolt holes) and companion flange inner side (socket diameter) using suitable tool. Runout limit Companion flange face: 0.10 mm (0.0039 in) Companion flange inner side: 0.13 mm (0.0051 in)
2. If the runout is outside the runout limit, follow the procedure below to adjust. Rotate the companion flange on the drive pinion by 90°, 180° and 270° while checking for the position where the runout is minimum. If the runout is still outside of the runout limit after the companion flange has been rotated on the drive pinion, possible cause could be an assembly malfunction of drive pinion and drive pinion bearing or a malfunctioning drive pinion bearing. If the runout is still outside of the runout limit after repair of the assembly of drive pinion and drive pinion bearing or drive pinion bearing, replace the companion flange.

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1. Remove carrier cover bolts.
2. Remove carrier cover using Tool. Tool number: KV10111100 (J-37228) CAUTION: Do not damage the mating surface. Do not insert flat-bladed screwdriver, this will damage the mating surface.
3. For proper reinstallation, paint matching mark on one side of side bearing cap. CAUTION: Side bearing caps are line-board for initial assembly. The matching marks are used to reinstall them in their original positions. For matching mark, use paint. Do not damage side bearing cap.
4. Remove adjuster lock plates.
5. Remove side bearing caps.
6. Remove side bearing adjusters using Tool. Tool number: - (C - 4164)
7. Keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusters together with bearing.
8. Remove side bearing adjusters from gear carrier.
9. Remove side bearing inner races using Tool. Tool number: ST33081000 ( - ) CAUTION: Do not damage differential case.
10. For proper reinstallation, paint matching mark on differential case and drive gear. CAUTION: Use paint for matching marks. Do not damage differential case or drive gear.
11. Remove drive gear bolts.
12. Tap the drive gear off the differential case using suitable tool. CAUTION: Tap evenly all around to keep drive gear from binding.
13. Remove the lock pin of the pinion mate shaft from the drive gear side using Tool. Tool number: ST23550000 ( - )
14. Remove pinion mate shaft.
15. Turn the pinion mate gear, then remove the pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from differential case.

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1. Remove differential case assembly. Refer to [ «REAR FINAL DRIVE ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375708-S02261239832010102800000) ].
2. Remove drive pinion lock nut and washer using Tool. Tool number: KV40104000 ( - )
3. Put matching marks on the companion flange and drive pinion using paint. CAUTION: Use paint to make the matching marks. Do not damage the companion flange or drive pinion.
4. Remove companion flange using suitable tool.
5. Remove front oil seal using Tool. Tool number: ST33290001 (J-34286) CAUTION: Do not damage gear carrier.
6. Remove drive pinion front bearing thrust washer.
7. Remove drive pinion assembly (with rear inner bearing race and collapsible spacer) out of gear carrier. CAUTION: Do not drop drive pinion assembly.
8. Remove drive pinion front bearing inner race from gear carrier.
9. Tap drive pinion front bearing outer race uniformly with a brass bar or equivalent to remove. CAUTION: Do not damage gear carrier.
10. Tap drive pinion rear bearing outer race uniformly with a brass bar or equivalent for removal. CAUTION: Do not damage gear carrier.
11. Remove drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool. Tool number: ST30021000 (J-22912-01)

1. If the drive pinion and drive gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or replace as necessary.
2. If the drive pinion or drive gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new drive pinion and drive gear.
3. Drive pinion and drive gear are supplied in matched sets only. Matching numbers on both drive pinion and drive gear are etched for verification. If a new drive pinion and drive gear set are being used, verify the numbers of each drive pinion and drive gear before proceeding with assembly.

1. If bearings are chipped (by friction), pitted, worn, rusted, scratched, or unusual noise is coming from bearing, replace with new bearing assembly (as a new set).
2. Bearing must be replaced with a new one whenever disassembled.

1. If any cracks or damage are found on the surface of the teeth, replace with new one.
2. If any worn or chipped marks are found on the side of the side gear and pinion mate gear which contact the thrust washer, replace with new one.
3. Replace both side gear and pinion mate gear as a set when replacing side gear or pinion mate gear.

1. If any chips (by friction), damage, or unusual wear are found, replace with new one.

1. If any wear or cracks are found on the contact sides of gear carrier, replace with new one.

1. If any chips (about 0.1mm, 0.004 in) or other damage on the companion flange surface which contacts the front oil seal lips are found, replace with new one.

1. Assemble the differential parts if they are disassembled. Refer to [ «REAR FINAL DRIVE ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375708-S02261239832010102800000) ].

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1. Place the differential case straight up so that the side gear to be measured is upward.
2. Using feeler gauges, measure the clearance between the side gear back and differential case at three different points, while rotating the side gear. Average the three readings to calculate the clearance. (Measure the clearance of the other side as well.) Side gear back clearance: 0.305 mm (0.0120 in) or less. If the side gear back clearance is outside of the specification, use a thicker or thinner side gear thrust washer to adjust. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S33102195872010102800000) ]. If the side gear back clearance is greater than specification: Use a thicker side gear thrust washer. If the side gear back clearance is less than specification: Use a thinner side gear thrust washer. CAUTION: Insert feeler gauges with the same thickness on both sides to prevent side gear from tilting. Each gear should rotate smoothly without excessive resistance during differential motion. Select a side gear thrust washer for right and left individually. NOTE: Side gear back clearance is clearance between side gear and differential case for adjusting side gear backlash.

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1. Drive gear and drive pinion are supplied in matched sets only. Matching numbers on both drive pinion and drive gear are etched for verification. If a new gear set is being used, verify the numbers of each drive pinion and drive gear before proceeding with assembly.
2. The mounting distance from the center line of drive gear to the back face of drive pinion for the Model 226 final drive assembly is 109.5 mm (4.312 in). On the button end of each drive pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0), which indicates the best running position for each particular gear set. This dimension is controlled by a selective drive pinion height adjusting washer between drive pinion inner bearing race and drive pinion. For example: If a drive pinion is etched m+8 (+3), it would require 0.08 mm (0.003 in) less drive pinion height adjusting washer than a drive pinion etched "0". This means decreasing drive pinion height adjusting washer thickness; increases the mounting distance of drive pinion to 109.6 mm (4.315 in). If a drive pinion is etched m-8 (-3), it would require adding 0.08 mm (0.003 in) more to drive pinion height adjusting washer than would be required if drive pinion were etched "0". By adding 0.08 mm (0.003 in), the mounting distance of drive pinion was decreased to 109.4 mm (4.309 in) which is just what m-8 (a-3) etching indicated.
3. To change drive pinion adjustment, use different drive pinion height adjusting washers which come in different thickness.
4. Use the following tables as a guide for selecting the correct drive pinion height adjusting washer thickness to add or subtract from the old drive pinion height adjusting washer. DRIVE PINION MARKING CHART OLD DRIVE PINION MARKING NEW DRIVE PINION MARKING mm (in) -10 (-4) -8 (-3) -5 (-2) -3 (-1) 0 (0) +3 (+1) +5 (+2) +8 (+3) +10 (+4) +10 (+4) +0.20 (+0.008) +0.18 (+0.007) +0.15 (+0.006) +0.13 (+0.005) +0.10 (+0.004) +0.08 (+0.003) +0.05 (+0.002) +0.02 (+0.001) 0 (0) +8 (+3) +0.18 (+0.007) +0.15 (+0.006) +0.13 (+0.005) +0.10 (+0.004) +0.08 (+0.003) +0.05 (+0.002) +0.02 (+0.001) 0 (0) -0.02 (-0.001) +5 (+2) +0.15 (+0.006) +0.13 (+0.005) +0.10 (+0.004) +0.08 (+0.003) +0.05 (+0.002) +0.02 (+0.001) 0 (0) -0.02 (-0.001) -0.05 (-0.002) +3 (+1) +0.13 (+0.005) +0.10 (+0.004) +0.08 (+0.003) +0.05 (+0.002) +0.02 (+0.001) 0 (0) -0.02 (-0.001) -0.05 (-0.002) -0.08 (-0.003) 0 (0) +0.10 (+0.004) +0.08 (+0.003) +0.05 (+0.002) +0.02 (+0.001) 0 (0) -0.02 (-0.001) -0.05 (-0.002) -0.08 (-0.003) -0.10 (-0.004) -3 (-1) +0.08 (+0.003) +0.05 (+0.002) +0.02 (+0.001) 0 (0) -0.02 (-0.001) -0.05 (-0.002) -0.08 (-0.003) -0.10 (-0.004) -0.13 (-0.005) -5 (-2) +0.05 (+0.002) +0.02 (+0.001) 0 (0) -0.02 (-0.001) -0.05 (-0.002) -0.08 (-0.003) -0.10 (-0.004) -0.13 (-0.005) -0.15 (-0.006) -8 (-3) +0.02 (+0.001) 0 (0) -0.02 (-0.001) -0.05 (-0.002) -0.08 (-0.003) -0.10 (-0.004) -0.13 (-0.005) -0.15 (-0.006) -0.18 (-0.007) -10 (-4) 0 (0) -0.02 (-0.001) -0.05 (-0.002) -0.08 (-0.003) -0.10 (-0.004) -0.13 (-0.005) -0.15 (-0.006) -0.18 (-0.007) -0.20 (-0.008)

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1. Make sure all parts are clean and that drive pinion bearings are well lubricated.
2. Assemble drive pinion bearings into Tools. Tool number A: - (8144) B: - (6740) C: - (6741)
3. Install drive pinion bearing inner race and drive pinion height adjusting washer to gear carrier using Tool as shown.
4. Turn the assembly several times to seat drive pinion bearings.
5. Measure the turning torque using Tool. Tool number: ST3127S000 (J-25765-A) Turning torque specification: 1.2 - 2.8 N-m (0.13 - 0.28 kg-m, 11 - 24 in-lb)
6. Tighten side bearing caps to the specified torque installing Tools as shown. Tool number A: - (6739) B: - (D-115-2) C: - (8541A-1) D: - (D-115-3)
7. Put scooter block on pinion height block. Make sure that dial indicator is level adjusting pressure with a hand. Dial indicator indicates "0".
8. Slide dial indicator along arbor. Record the maximum.
9. Adjust drive pinion height adjusting washer so that the maximum will be "0".

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1. Press a new drive pinion rear bearing outer race into gear carrier using Tools. Tool number A: ST01500001 ( - ) B: ST30022000 ( - ) CAUTION: Do not reuse drive pinion rear bearing.
2. Press a new drive pinion front bearing outer race into gear carrier using Tool. Tool number: ST33022000 ( - ) CAUTION: Do not reuse drive pinion front bearing.
3. Select drive pinion height adjusting washer. Refer to [ «REAR FINAL DRIVE ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375708-S02261239832010102800000) ].
4. Press a new drive pinion rear bearing inner race and drive pinion height adjusting washer to drive pinion using Tool. Tool number: - (C - 4040) CAUTION: Do not reuse drive pinion rear bearing.
5. Apply gear oil to drive pinon rear bearing and drive pinon front bearing.
6. Install a new drive pinion front bearing inner race in gear carrier.
7. Install drive pinion front bearing thrust washer to gear carrier.
8. Apply multi-purpose grease to new front oil seal lip. Install new front oil seal into gear carrier using Tool. Tool number: ST15310000 ( - ) CAUTION: Do not reuse front oil seal. Do not incline the new front oil seal when installing. Apply multi-purpose grease to the lip of the new front oil seal.
9. Install new collapsible spacer to drive pinion. And then install drive pinion assembly in gear carrier. CAUTION: Do not reuse collapsible spacer. Do not damage front oil seal.
10. Install the companion flange onto the drive pinion while aligning the matching marks. Then tap the companion flange using suitable tool. CAUTION: Do not damage companion flange or front oil seal.
11. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut and new drive pinion lock nut washer. Then adjust the drive pinion lock nut tightening torque using Tool A, and check the drive pinion bearing preload torque using Tool B. Tool number A: KV40104000 ( - ) B: ST3127S000 (J-25765-A) Drive pinion bearing preload torque: 1.7 - 3.1 N.m (0.18 - 0.31 kg-m, 15 - 27 in-lb) CAUTION: Do not reuse drive pinion lock nut or drive pinion lock nut washer. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut. Adjust the drive pinion lock nut tightening torque to the lower limit first. Do not exceed the drive pinion lock nut specified torque. Refer to [ «REAR FINAL DRIVE ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375708-S02261239832010102800000) ]. If the drive pinion bearing preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Do not loosen drive pinion lock nut to adjust the drive pinion bearing preload torque. After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.

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1. Assemble side gear thrust washers with the same thickness as the ones installed prior to disassembly or reinstall the old ones on side gears.
2. Assemble side gear and side gear thrust washer into differential case.
3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and assemble them into differential case after assembling pinion mate thrust washer to pinion mate gear.
4. Align lock pin holes on differential case and shaft, and assemble pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to [ «REAR FINAL DRIVE ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375708-S02261239832010102800000) ].
6. Drive a new lock pin into pinion mate shaft, using Tool. Tool number: ST23550000 ( - ) CAUTION: Do not reuse lock pin.
7. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly.
8. Apply thread locking sealant to the back face of drive gear as shown. Use Genuine High Strength Thread Locking Sealant, Loctite 648 or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ] CAUTION: Make sure the drive gear back and threaded holes are clean.
9. Align the matching mark of differential case with the mark of drive gear, then install drive gear.
10. Apply thread locking sealant into the threaded holes of the drive gear and install the bolts. Use Genuine High Strength Thread Locking Sealant, Loctite 648 or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ] CAUTION: Make sure the drive gear back and threaded holes are clean.
11. Install new drive gear bolts, and then tighten to the specified torque. Refer to [ «REAR FINAL DRIVE ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375708-S02261239832010102800000) ]. CAUTION: Do not reuse the bolts. Tighten bolts in a crisscross fashion.
12. Press new side bearing inner races to differential case using Tools. Tool number A: KV38100300 (J-25523) B: ST33081000 ( - ) CAUTION: Do not reuse side bearing.
13. Install side bearing adjusters into gear carrier.
14. Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into gear carrier.
15. Align paint matching mark on side bearing caps with that on gear carrier and install side bearing caps on gear carrier. CAUTION: Do not tighten at this point. This allows further tightening of side bearing adjusters.
16. Tighten each side bearing adjusters using Tool. Tool number: - (C - 4164)
17. Adjusting backlash of drive gear and drive pinion. Refer to [ «REAR FINAL DRIVE ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375708-S02261239832010102800000) ].
18. Check total preload. Refer to [ «REAR FINAL DRIVE ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375708-S02261239832010102800000) ].
19. Check tooth contact. Refer to [ «REAR FINAL DRIVE ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375708-S02261239832010102800000) ].
20. Apply a bead of sealant to the mating surface of the carrier cover as shown. Use Genuine Silicone RTV or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ] CAUTION: Remove any old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to the application and mating surfaces.
21. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Refer to [ «REAR FINAL DRIVE ASSEMBLY: DISASSEMBLY AND ASSEMBLY»(ref-375708-S02261239832010102800000) ].

ITEM STANDARD CHART

COMPANION FLANGE RUNOUT CHART

Drive Pinion Height Adjusting Washer

DRIVE PINION HEIGHT ADJUSTING WASHER THICKNESS CHART

Side Gear Thrust Washer

SIDE GEAR THRUST WASHER CHART

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

SPECIAL SERVICE TOOL REFERENCE Tool number (Kent-Moore No.) Tool name Description KV40104000 ( - ) Flange wrench Removing and installing drive pinion nut 85 mm (3.35 in) dia. 65 mm (2.56 in) dia. ST33290001 (J-34286) Puller Removing front oil seal ST15310000 ( - ) Drift Installing front oil seal 96 mm (3.77 in) dia. 84 mm (3.30 in) dia. ST3127S000 (J-25765-A) Preload gauge set GG91030000 (J-25765) Torque wrench HT62940000 (1/2") ( - ) Socket adapter HT62900000 (3/8") ( - ) Socket adapter Inspecting drive pinion bearing preload and total preload - (C-4164) Adjuster tool Removing and installing side bearing adjuster KV10111100 (J-37228) Seal cutter Removing carrier cover ST30021000 (J-22912-01) Puller Removing drive pinion rear bearing inner race ST33081000 ( - ) Adapter Removing and installing side bearing inner race 43 mm (1.69 in) dia. 33.5 mm (1.32 in) dia. ST23550000 ( - ) Pin punch Removing and installing lock pin 4.5 mm (0.177 in) dia. - (8144) Pinion block Adjusting pinion gear height - (6740) Cone Adjusting pinion gear height - (6741) Screw Adjusting pinion gear height - (6739) Pinion height lock Adjusting pinion gear height - (D-115-2) Scooter block Adjusting pinion gear height - (8541A-1) Arbor disc Adjusting pinion gear height - (D-115-3) Arbor Adjusting pinion gear height ST01500001 ( - ) Drift Installing drive pinion rear bearing outer race 89 mm (3.50 in) dia. 79 mm (3.11 in) dia. ST30022000 ( - ) Drift Installing drive pinion rear bearing outer race 46 mm (1.81 in) dia. 110 mm (4.33 in) dia. ST33022000 ( - ) Drift Installing drive pinion front bearing outer race 49 mm (1.92 in) dia. 67 mm (2.63 in) dia. - (C-4040) Installer Installing drive pinion rear bearing inner race KV38100300 (J-25523) Drift Installing side bearing inner race 54 mm (2.13 in) dia. 46 mm (1.81 in) dia. 32 mm (1.26 in) dia

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COMMERCIAL SERVICE TOOL REFERENCE Tool name Description Puller Removing companion flange and side bearing inner race Puller Removing side bearing inner race Power tool Loosening bolts and nuts

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1. Before connecting or disconnecting differential lock control unit harness connector, turn ignition switch "OFF" and disconnect the battery cable from the negative terminal. Because battery voltage is applied to differential lock control unit even if ignition switch is turned "OFF".
2. When connecting or disconnecting pin connectors into or from differential lock control unit, take care not to damage pin terminals (bend or break). When connecting pin connectors make sure that there are not any bends or breaks on differential lock control unit pin terminal.
3. Before replacing differential lock control unit, perform differential lock control unit input/output signal inspection and make sure whether differential lock control unit functions properly or not. Refer to [ «SDT FUNCTION (DIFF LOCK)»(ref-375708-S26426603002010102800000) ].

1. Before starting diagnosis of the vehicle, understand the symptoms well. Perform correct and systematic operations.
2. Check for the correct installation status prior to removal or disassembly. When matching marks are required, be certain they do not interfere with the function of the parts they are applied to.
3. Overhaul should be done in a clean work area, a dust proof area is recommended.
4. Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from entering into the unit during disassembly or assembly.
5. Always use shop paper for cleaning the inside of components.
6. Avoid using cotton gloves or a shop cloth to prevent the entering of lint.
7. Check appearance of the disassembled parts for damage, deformation, and abnormal wear. Replace them with new ones if necessary.
8. Gaskets, seals and O-rings should be replaced any time the unit is disassembled.
9. Clean and flush the parts sufficiently and blow them dry.
10. Be careful not to damage sliding surfaces and mating surfaces.
11. When applying sealant, remove the old sealant from the mating surface; then remove any moisture, oil, and foreign materials from the application and mating surfaces.
12. In principle, tighten nuts or bolts gradually in several steps working diagonally from inside to outside. If a tightening sequence is specified, observe it.
13. During assembly, observe the specified tightening torque.
14. Add new differential gear oil, petroleum jelly, or multi-purpose grease, as specified.

Scheme 337

The differential lock system consists of the following components

1. Differential lock control unit
2. Differential lock mode switch
3. Differential lock position switch
4. Differential lock solenoid
5. ABS actuator and electric unit (control unit)
6. Transfer control unit

When the differential lock mode switch is in the LOCK position, a signal is sent to the differential lock control unit. The differential lock control unit monitors input from the ABS actuator and electric unit (vehicle speed and VDC operation) and the transfer control unit (4WD shift switch). If conditions are set, the differential lock control unit provides power and ground to the differential lock solenoid to lock the differential. The differential lock position switch provides feedback to the differential lock control unit as to whether the lock is engaged based on pressure plate position. The differential lock control unit provides ground to the DIFF LOCK indicator lamp to activate the lamp. Refer to the Owner's Manual for differential lock system operating instructions.

As a fail-safe function, the differential lock disengages when a malfunction is detected in the differential lock system. "DTC check" can be performed using SDT. Refer to [ SDT FUNCTION (DIFF LOCK) ].

Scheme 338

1. Differential lock solenoid operates pressure plate.
2. Pressure plate presses cam ring.
3. Engage cam ring and side gear, and the differential is locked.

DIFFERENTIAL LOCK INDICATOR LAMP OPERATION CHART

Note. The differential lock standby condition is the time where the differential lock mode switch is in the LOCK position and the differential is unlocked.

COMPONENT FUNCTION CHART

Scheme 339

Scheme 340

DETAILED FLOW

SYMPTOM CHART

SDT Function (Diff Lock)

SDT can display each diagnostic item using the following diagnostic test modes

DIFFERENTIAL LOCK DIAGNOSTIC TEST MODE FUNCTION CHART

Data List

Display Item List

ITEM DESCRIPTION

Component Function Check

COMPONENT FUNCTION CHART

DIFF Lock Indicator Lamp Inoperative

SYMPTOM

DIFF LOCK indicator lamp does not turn ON for approx. 1 second when turning ignition switch to "ON".

Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive pinion. Gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check gear tooth contact pattern to obtain the best contact for low noise and long life.

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Scheme 343

1. Thoroughly clean drive gear and drive pinion teeth.
2. Apply red lead to the drive gear. NOTE: Apply red lead to both faces of three to four gears, at four locations evenly spaced on the drive gear.
3. Hold companion flange steady by hand and rotate drive gear in both directions.
4. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S36684510132010102800000) ].

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1. Fit a dial indicator to the drive gear face to measure the backlash. Backlash: 0.12 - 0.20 mm (0.0050 - 0.0078 in)
2. If the backlash is outside of the specification, adjust each side bearing side bearing adjuster. Remove adjuster lock plate. Loosen side bearing cap bolts. Tighten or loosen each side bearing adjusters using Tool. Tool number: - (C - 4164) If the backlash is greater than specification: Loosen side bearing adjuster A and tighten side bearing adjuster B by the same amount. If the backlash is less than specification: Loosen side bearing adjuster B and tighten side bearing adjuster A by the same amount. CAUTION: Do not change the side bearing side bearing adjusters by different amounts as it will change the side bearing preload torque. Tighten side bearing cap bolts to the specified torque. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ]. Install adjuster lock plate and tighten to the specified torque. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ]. CAUTION: Check tooth contact and total preload torque after adjusting side bearing adjuster. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S36684510132010102800000) ].

Scheme 348

1. Rotate companion flange and check for runout on the companion flange face (inner side of the bolt holes) and companion flange inner side (socket diameter) using suitable tool. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S36684510132010102800000) ].
2. If the runout is outside the runout limit, follow the procedure below to adjust. Rotate the companion flange on the drive pinion by 90°, 180° and 270° while checking for the position where the runout is minimum. If the runout is still outside of the runout limit after the companion flange has been rotated on the drive pinion, possible cause could be an assembly malfunction of drive pinion and drive pinion bearing or a malfunctioning drive pinion bearing. If the runout is still outside of the runout limit after repair of the assembly of drive pinion and drive pinion bearing or drive pinion bearing, replace the companion flange.

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Scheme 354

1. Remove carrier cover bolts.
2. Remove carrier cover using Tool. Tool number: KV10111100 (J-37228) CAUTION: Do not damage the mating surface. Do not insert flat-bladed screwdriver, this will damage the mating surface.
3. Remove differential sensor connector bolts and differential lock solenoid connector.
4. For proper reinstallation, paint matching mark on one side of side bearing cap. CAUTION: Side bearing caps are line-board for initial assembly. The matching marks are used to reinstall them in their original positions. For matching mark, use paint. Do not damage side bearing cap.
5. Remove adjuster lock plates.
6. Remove side bearing caps.
7. Loosen side bearing adjusters using Tool.
8. Remove differential lock position switch. Tool number: - (C - 4164)
9. Remove differential lock position switch bracket.
10. Remove the differential case assembly. Label side bearing outer races to keep them together with inner races. Do not mix them up.

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1. Put matching marks on the companion flange at location (A) and drive pinion using paint as shown. CAUTION: Use paint to make the matching marks. Do not damage the companion flange or drive pinion.
2. Remove drive pinion lock nut and washer using suitable tool. Tool number: KV40104000 ( - )
3. Remove companion flange using a suitable tool.
4. Remove oil seal/dust shield and discard. CAUTION: Do not reuse the differential oil seal.
5. Remove front oil seal using Tool. Tool number: ST33290001 (J-34286)
6. Remove drive pinion front bearing thrust washer.
7. Remove drive pinion assembly (with rear inner bearing race and collapsible spacer) out of gear carrier. CAUTION: Do not drop drive pinion assembly.
8. Remove collapsible spacer from drive pinion assembly and discard collapsible spacer. CAUTION: Do not reuse the collapsible spacer.

1. If the gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or replace as necessary.
2. If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new gears.

1. If bearings are chipped (by friction), pitted, worn, rusted, scratched mark, or unusual noise from the bearing, replace with new rear final drive assembly.

1. If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new rear final drive assembly.
2. If the movement is not smooth when pushing cam ring of differential case assembly by hand. Replace with new rear final drive assembly.

1. If the operating part of differential lock solenoid is not smooth, perform component inspection. Refer to [ «SDT FUNCTION (DIFF LOCK)»(ref-375708-S26426603002010102800000) ].

Scheme 359

1. Drive gear and drive pinion are supplied in matched sets only. Matching numbers on both drive pinion and drive gear are etched for verification. If a new gear set is being used, verify the numbers of each drive pinion and drive gear before proceeding with assembly.
2. The mounting distance from the center line of drive gear to the back face of drive pinion for the Model 226 final drive assembly is 109.5 mm (4.312 in). On the button end of each drive pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0), which indicates the best running position for each particular gear set. This dimension is controlled by a selective drive pinion height adjusting washer between drive pinion inner bearing race and drive pinion. For example: If a drive pinion is etched m+8 (+3), it would require 0.08 mm (0.003 in) less drive pinion height adjusting washer than a drive pinion etched "0". This means decreasing drive pinion height adjusting washer thickness; increases the mounting distance of drive pinion to 109.6 mm (4.315 in). If a drive pinion is etched m-8 (-3), it would require adding 0.08 mm (0.003 in) more to drive pinion height adjusting washer than would be required if drive pinion were etched "0". By adding 0.08 mm (0.003 in), the mounting distance of drive pinion was decreased to 109.4 mm (4.309 in) which is just what m-8 (a-3) etching indicated.
3. To change drive pinion adjustment, use different drive pinion height adjusting washers which come in different thickness.
4. Use the following tables as a guide for selecting the correct drive pinion height adjusting washer thickness to add or subtract from the old drive pinion height adjusting washer. WASHER THICKNESS CHART OLD DRIVE PINION MARKING NEW DRIVE PINION MARKING mm (in) -10 (-4) -8 (-3) -5 (-2) -3 (-1) 0 (0) 3 (+1) +5 (+2) +8 (+3) +10 (+4) +10 (+4) +0.20 (+0.008) +0.18 (+0.007) +0.15 (+0.006) +0.13 (+0.005) +0.10 (+0.004) +0.08 (+0.003) +0.05 (+0.002) +0.02 (+0.001) 0 (0) +8 (+3) +0.18 (+0.007) +0.15 (+0.006) +0.13 (+0.005) +0.10 (+0.004) +0.08 (+0.003) +0.05 (+0.002) +0.02 (+0.001) 0 (0) -0.02 (-0.001) +5 (+2) +0.15 (+0.006) +0.13 (+0.005) +0.10 (+0.004) +0.08 (+0.003) +0.05 (+0.002) +0.02 (+0.001) 0 (0) -0.02 (-0.001) -0.05 (-0.002) +3 (+1) +0.13 (+0.005) +0.10 (+0.004) +0.08 (+0.003) +0.05 (+0.002) +0.02 (+0.001) 0 (0) -0.02 (-0.001) -0.05 (-0.002) -0.08 (-0.003) 0 (0) +0.10 (+0.004) +0.08 (+0.003) +0.05 (+0.002) +0.02 (+0.001) 0 (0) -0.02 (-0.001) -0.05 (-0.002) -0.08 (-0.003) -0.10 (-0.004) -3 (-1) +0.08 (+0.003) +0.05 (+0.002) +0.02 (+0.001) 0 (0) -0.02 (-0.001) -0.05 (-0.002) -0.08 (-0.003) -0.10 (-0.004) -0.13(-0.005) 5 (-2) +0.05 (+0.002) +0.02 (+0.001) 0 (0) -0.02 (-0.001) -0.05 (-0.002) -0.08 (-0.003) -0.10 (-0.004) -0.13 (-0.005) -0.15 (-0.006) -8 (-3) +0.02 (+0.001) 0 (0) -0.02 (-0.001) -0.05 (-0.002) -0.08 (-0.003) -0.10 (-0.004) -0.13 (-0.005) -0.15 (-0.006) -0.18 (-0.007) -10 (-4) 0 (0) -0.02 (-0.001) -0.05 (-0.002) -0.08 (-0.003) -0.10 (-0.004) -0.13 (-0.005) -0.15 (-0.006) -0.18 (-0.007) -0.20 (-0.008)

Scheme 360

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1. Make sure all parts are clean and that drive pinion bearings are well lubricated.
2. Assemble drive pinion bearings into the tools. Tool number A: - (8144) B: - (6740) C: - (6741)
3. Install drive pinion bearing inner race and drive pinion height adjusting washer to gear carrier using tool as shown.
4. Turn the assembly several times to seat drive pinion bearings.
5. Measure the turning torque, using Tool. Tool number: ST3127S000 (J-25765 -A) Turning torque specification: 1.2 - 2.8 N-m (0.13 - 0.28 kg-m, 11 - 24 in-lb)
6. Tighten side bearing caps to the specified torque installing tools as shown. Tool number A: - (6739) B: - (D-115-2) C: - (8541A-1) D: - (D-115-3)
7. Put scooter block on pinion height block. Make sure that dial indicator is level adjusting pressure with a hand. Dial indicator indicates "0".
8. Slide dial indicator along arbor. Record the maximum.
9. Adjust drive pinion height adjusting washer so that the maximum will be "0".

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1. Press a drive pinion rear bearing outer race into gear carrier using Tool. Tool number A: ST01500001 ( - ) B: ST30022000 ( - ) CAUTION: Do not reuse drive pinion rear bearing.
2. Press a drive pinion front bearing outer race into gear carrier using Tool. Tool number: ST33022000 ( - ) CAUTION: Do not reuse drive pinion front bearing.
3. Select drive pinion height adjusting washer. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S36684510132010102800000) ].
4. Press a drive pinion rear bearing inner race and drive pinion height adjusting washer to drive pinion, using Tool. Tool number: - (C - 4040) CAUTION: Do not reuse drive pinion rear bearing.
5. Apply gear oil to drive pinon rear bearing and drive pinon front bearing.
6. Install drive pinion front bearing inner race in gear carrier.
7. Install drive pinion front bearing thrust washer to gear carrier.
8. Apply multi-purpose grease to front oil seal lip. Install front oil seal into gear carrier using Tool. Tool number: ST15310000 ( - ) CAUTION: Do not reuse front oil seal. Do not incline the new front oil seal when installing. Apply multi-purpose grease to the lips of the new front oil seal.
9. Install collapsible spacer to drive pinion. And then install drive pinion assembly in gear carrier. CAUTION: Do not reuse collapsible spacer. Do not damage front oil seal.
10. Install the companion flange to the drive pinion while aligning the matching marks.
11. Install the companion flange onto the drive pinion while aligning the matching marks. Then tap the companion flange using suitable tool. CAUTION: Do not damage companion flange or front oil seal.
12. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut and new drive pinion lock nut washer. Then adjust the drive pinion lock nut tightening torque using Tool A, and check the drive pinion bearing preload torque using Tool B. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S36684510132010102800000) ]. Tool number A: KV40104000 ( - ) B: ST3127S000 (J-25765-A) CAUTION: Do not reuse drive pinion lock nut or drive pinion lock nut washer. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut. Adjust the drive pinion lock nut tightening torque to the lower limit first. Do not exceed the drive pinion lock nut specified torque. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ]. If the drive pinion bearing preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Do not loosen drive pinion lock nut to adjust the drive pinion bearing preload torque. After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.

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1. Align the matching mark of differential case assembly with the mark of drive gear, then install drive gear.
2. Apply thread locking sealant into the threaded holes of the drive gear and install the bolts. Use Genuine Medium Strength Thread Locking Sealant or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ] CAUTION: Make sure the drive gear back and threaded holes are clean.
3. Install new drive gear bolts, and then tighten to the specified torque. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ]. CAUTION: Do not reuse the bolts. Tighten bolts in a crisscross fashion.
4. Press side bearing inner races to differential case assembly using Tool. Tool number: ST33081000 ( - ) CAUTION: Do not reuse side bearing.
5. Install differential lock solenoid and washer.
6. Press side bearing inner races to differential case assembly using Tool. Tool number A: KV38100300 (J-25523) B: ST33081000 ( - )
7. Apply sealant to threads of differential lock position switch. Use Genuine Silicone RTV or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ] CAUTION: Remove old sealant adhering to gear carrier and differential lock position switch. Also remove any moisture, oil, or foreign material adhering to application and gear carrier and differential lock position switch.
8. Install differential lock position switch on gear carrier and tighten differential lock position switch bolts with the specified torque. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ].
9. Install side bearing adjusters into gear carrier.
10. Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into gear carrier.
11. Apply multi-purpose grease to sensor connector. CAUTION: Do not reuse sensor connector.
12. Connect differential lock solenoid harness and sensor connector. Then install it to gear carrier, tighten to the specified torque. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ].
13. Align paint matching mark on side bearing caps with that on gear carrier and install side bearing caps on gear carrier. CAUTION: Do not tighten at this point. This allows further tightening of side bearing adjusters.
14. Tighten each side bearing adjusters using adjuster tool. Tool number: - (C - 4164)
15. Adjusting backlash of drive gear and drive pinion. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S36684510132010102800000) ].
16. Check total preload. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S36684510132010102800000) ].
17. Check tooth contact. Refer to [ «SERVICE DATA AND SPECIFICATIONS»(ref-375708-S36684510132010102800000) ].
18. Apply a bead of sealant to the mating surface of the carrier cover as shown. Use Genuine Silicone RTV or equivalent. Refer to [ «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) ] CAUTION: Remove any old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to the application and mating surfaces.
19. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Refer to [ «REAR FINAL DRIVE: DISASSEMBLY AND ASSEMBLY»(ref-375708-S23287811472010102800000) ].

ITEM STANDARD

COMPANION FLANGE RUNOUT CHART

Drive Pinion Height Adjusting Washer

PART THICKNESS CHART

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

ITEM DESCRIPTION Tool number (Kent-Moore No.) Tool name Description KV40104000 ( - ) Flange wrench Removing and installing drive pinion lock nut 85 mm (3.35 in) dia. 65 mm (2.56 in) dia. ST33290001 (J-34286) Puller Removing front oil seal ST15310000 ( - ) Drift Installing front oil seal 96 mm (3.77 in) dia. 84 mm (3.30 in) dia. ST3127S000 (J-25765-A) Preload gauge set GG91030000 (J-25765) Torque wrench HT62940000 (1/2") ( - ) Socket adapter HT62900000 (3/8") ( - ) Socket adapter Inspecting drive pinion bearing preload torque and total preload torque - (C-4164) Adjuster tool Removing and installing side bearing adjuster KV10111100 (J-37228) Seal cutter Removing carrier cover ST30021000 (J-22912-01) Puller Removing drive pinion rear bearing inner race ST33081000 ( - ) Adapter Removing and installing side bearing inner race 43 mm (1.69 in) dia. 33.5 mm (1.32 in) dia. - (8144) Drive pinion block Adjusting drive pinion height - (6740) Cone Adjusting drive pinion height - (6741) Screw Adjusting drive pinion height - (6739) Drive pinion height lock Adjusting drive pinion height - (D-115-2) Scooter block Adjusting drive pinion height - (8541A-1) Arbor disc Adjusting drive pinion height - (D-115-3) Arbor Adjusting drive pinion height ST01500001 ( - ) Drift Installing drive pinion rear bearing outer race 89 mm (3.50 in) dia. 79 mm (3.11 in) dia. ST30022000 ( - ) Drift Installing drive pinion rear bearing outer race 46 mm (1.81 in) dia. 110 mm (4.33 in) dia. ST33022000 ( - ) Drift Installing drive pinion front bearing outer race 49 mm (1.92 in) dia. 67 mm (2.63 in) dia. - (C-4040) Installer Installing drive pinion rear bearing inner race KV38100300 (J-25523) Drift Installing side bearing inner race 54 mm (2.13 in) dia. 46 mm (1.81 in) dia. 32 mm (1.26 in) dia

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COMMERCIAL SERVICE TOOL REFERENCE Tool name Description Puller Removing companion flange and side bearing inner race Puller Removing side bearing inner race Power tool Loosening bolts and nuts

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