|
Use the following special tools to
insert the oil seal, and then apply a thin coat of
multipurpose grease to the lip of the oil
seal.
- Installer bar (MB990938)
- Installer adapter (MB990934)
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|
Use the following special tools to
press-fit the drive pinion rear bearing outer races into the
gear carrier.
- Installer bar (MB990938)
- Installer adapter (MB990936)
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Use the following special tools to
press-fit the drive pinion rear bearing outer races into the
gear carrier.
- Installer bar (MB990938)
- Installer adapter (MB990934)
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|
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Adjust the drive pinion height by
the following procedure.
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1.Apply multipurpose grease
to the washer of following special tools.
- Drive pinion gauge assembly (MB990819) <Except
3000-A/T>
- Drive pinion gauge assembly (MB990903)
<3000-A/T>
2. Install the special tool, drive pinion front
and rear bearing inner races to the gear carrier.
| caution |
There should be no gear oil
adhered to the bearing.
|
|
|
3.Tighten the nut of special
tool while measuring the turning torque of the drive pinion
by using the following special tools. Gradually keep
tightening the nut of special tool until the turning torque
of the drive pinion (without oil seal) is at the standard
value.
- Preload socket (MB990326)
- Torque wrench (MB990685)
- Drive pinion gauge assembly (MB990819) <Except
3000-A/T>
- Drive pinion gauge assembly (MB990903)
<3000-A/T>
Standard value :
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|
Bearing
division
|
Bearing
lubrication
|
Bearing lubrication
N·m
|
New
|
None (with anti-rust
agent)
|
0.83 - 1.19
|
|
| note |
Because special tool preload
socket (MB990326) cannot be turned one turn,
turn it several times within the range that it
can be turned; then, after fitting to the
bearing, measure the turning torque.
|
4.Clean the side bearing hub.
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5.Place the special tool
cylinder gauge (MB991170) in the side bearing seat of the
differential carrier, and position the notch as shown in the
illustration. Then install the bearing caps.
| note |
Always check that the notch is
in the shown position and that special tools are
touching firmly against the side bearing
hub.
|
6.Use a thickness gauge to measure the
clearance (A) between special tools.
7.Remove
special tools.
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|
8.Use a micrometer to
measure the special tool in the places (B, C) shown in the
illustration
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9.Install the bearing cap,
and then use a cylinder gauge and micrometer to measure the
inside diameter (D) of the bearing cap as shown in the
illustration.
10.Calculate the thickness (E) of
the required drive pinion rear shim by the following
formula, and then select a shim which most closely matches
this thickness.
E = A + B + C
- 1/2D - 100.0 mm <Except 3000-A/T>
E
= A + B + C - 1/2D - 91.0 mm
<3000-A/T>
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11.Fit the selected drive
pinion rear shim(s) to the drive pinion, and press-fit the
drive pinion rear bearing inner race by using special tool
bearing installer (MB990802).
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Adjust the drive pinion rotation
torque by using the following procedure:
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|
|
1.Insert the drive pinion
into the gear carrier, and then install the drive pinion
spacer, the drive pinion front shim, the drive pinion front
bearing inner race, and the companion flange in that
order.
| note |
Do not install the oil
seal.
|
|
|
2.Tighten the companion
flange self-locking nut to the specified torque while
holding the companion flange with special tool front hub and
flange yoke holder (MB990767).
Tightening
torque : 216 ± 29 N·m <Except
3000-A/T>, 187 ± 29 N·m
<3000-A/T>
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3.
| caution |
There should be no gear oil
adhered to the bearing.
|
Use the following special tools to measure the drive
pinion turning torque (without the oil
seal).
- Preload socket (MB990326)
- Torque wrench (MB990685)
Standard value :
|
|
Bearing
division
|
Bearing
lubrication
|
Turning torque
N·m
|
New
|
None (with anti-rust
agent)
|
0.83 - 1.19
|
|
|
|
4.If the drive pinion
turning torque is not within the range of the standard
value, adjust the preload by replacing the drive pinion
front shim(s) or the drive pinion spacer.
| note |
When selecting the drive
pinion front shims, if the number of shims is
large, reduce the number of shims to a minimum
by selecting the drive pinion spacers. Also,
select respectively drive pinion spacer from the
following two types for applicable
models.
|
|
Height
of drive pinion
spacer
mm
|
Identification
colour
|
Applicable
models
|
56.67
|
White
|
Except
3000-A/T
|
57.01
|
-
|
46.67
|
White
|
3000-A/T
|
47.01
|
-
|
|
|
| note |
Apply gear oil around the
circumference of companion flange (and the
mating surface of oil seal) when press fitting
oil seal into companion flange.
|
|
|
5.Remove the companion
flange and drive pinion again. Then, after inserting the
drive pinion front bearing inner race into the gear carrier,
use the following special tools to press-fit the oil
seal.
- Differential oil seal installer (MB991168)
<Except 3000-A/T>
- Pinion shaft oil seal installer driver (MB990031)
<3000-A/T>
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|
6.Install the drive pinion
assembly and companion flange with the mating marks properly
aligned. Tighten the companion flange self-locking nut to
the specified torque while holding the companion flange with
special tool.
Tightening torque : 216 ±
29 N·m <Except 3000-A/T>, 187 ±
29 N·m <3000-A/T>
|
|
7.Use the following special
tools to measure the drive pinion turning torque (with drive
pinion oil seal) to verify that the drive pinion turning
torque complies with the standard value.
- Preload socket (MB990326)
- Torque wrench (MB990685)
Standard value:
|
|
Bearing
division
|
Bearing
lubrication
|
Turning torque
N·m
|
New
|
None (with anti-rust
agent)
|
0.89 - 1.78
|
Gear oil
applied
|
0.97 - 1.32
|
|
8.If the drive pinion turning torque is not
within the standard value, check the tightening torque of
the companion flange self-locking nut and the oil
seal.
|
|
1.Assemble the side gears,
side gear spacers, pinion gears and pinion washers into the
differential case.
2.Temporarily install the
pinion shaft.
| note |
Do not drive in the lock pin
yet.
|
|
|
3.Insert a wedge between the
side gear and the pinion shaft to lock the side
gear.
4.While locking the side gear with the
wedge, measure the differential gear backlash with a dial
indicator on the pinion gear.
Standard value:
0.01 - 0.250 mm
Measure by the same procedure for
the other pinion gear.
5.If the backlash exceeds
the standard value, adjust it by replacing the side gear
spacers.
6.If adjustment is not possible, replace
the side gears and pinion gears as a
set.
7.Measure the differential gear backlash once
again, and confirm that it is within the limit.
|
|
1.Align the pinion shaft
lock pin hole with the differential case lock pin hole, and
drive in the lock pin.
2.Stake the lock pin with a
punch at two points.
|
|
|
1.Clean the drive gear
attaching bolts.
|
|
2.Remove the adhesive
adhered to the threaded holes of the drive gear by turning
the tap (M10 × 1.25), and then clean the threaded
holes by applying compressed air.
|
|
3.Apply the specified
sealant to the threaded holes of the drive
gear.
Specified sealant: LOCKTITE No.271 or
No.270 or equivalent
4.Install the drive
gear onto the differential case with the mating marks
properly aligned. Tighten the bolts to the specified torque
in a diagonal sequence.
Tightening torque: 84
± 4 N·m
|
|
Use special tool bearing installer
(MB990802) to press-fit the differential side bearing inner
races into the differential case.
|
|
|
Adjust the drive gear backlash by
the following procedures:
|
|
1.Install the side bearing
spacers, which are thinner than those removed, to the side
bearing outer races, and then mount the differential case
assembly into the gear carrier.
| note |
Select side bearing spacers
with the same thickness for both the drive
pinion side and the drive gear side.
|
|
|
2.Push the differential case
assembly to one side, and measure the clearance between the
gear carrier and the side bearing adjusting spacer with a
thickness gauge.
|
|
3.Measure the thickness of
the side bearing adjusting spacers on one side, select two
pairs of spacers which correspond to that thickness plus one
half of the clearance plus 0.05 mm, and then install one
pair each to the drive pinion side and the drive gear
side.
|
|
4.Install the side bearing
adjusting spacers and differential case assembly, as shown
in the illustration, to the gear carrier.
|
|
5.Tap the side bearing
adjusting spacers with special tool Installer bar (MB990939)
to fit them to the side bearing outer
race.
6.Align the mating marks on the gear carrier
and the bearing cap, and then tighten the bearing
cap.
Tightening torque: 59 ± 4
N·m
|
|
7.With the drive pinion
locked in place, measure the drive gear backlash with a dial
indicator on the drive gear.
| note |
Measure at four points or more
on the circumference of the drive gear.
|
Standard value: 0.11 - 0.16
mm
|
|
8.Change the side bearing
adjusting spacers as illustrated, and then adjust the drive
gear backlash between the drive gear and the drive
pinion.
| note |
When increasing the number of
side bearing adjusting spacers, use the same
number for each, and as few as
possible.
|
9.Check the drive gear and drive pinion for
tooth contact. If poor contact is evident, make adjustment.
(Refer to  )
10.Measure
the drive gear runout at the shoulder on the reverse side of
the drive gear.
Limit: 0.05
mm
11.If the drive gear runout exceeds the
limit, reinstall by changing the phase of the drive gear and
differential case, and remeasure.
12. If
adjustment is not possible, replace the differential case or
replace the drive gear and drive pinion as a set.
|
