REASSEMBLY

Reassembly steps 1. Differential carrier >>A<< 2. Oil seal >>B<< 3. Drive pinion rear bearing outer race >>C<< 4. Drive pinion front bearing outer race >>D<< · Drive pinion height adjustment 5. Drive pinion 6. Drive pinion rear shim (for adjusting drive pinion height) 7. Drive pinion rear bearing inner race 8. Drive pinion spacer >>E<< · Drive pinion turning torque adjustment 9. Drive pinion front shim (for adjusting preload of drive pinion) 10. Drive pinion assembly 11. Drive pinion front bearing inner race >>E<< 12. Oil seal 13. Companion flange 14. Washer 15. Self-locking nut 16. Differential case >>F<< · Differential gear backlash adjustment 17. Side gear spacer 18. Side gear 19. Pinion washer 20. Pinion gear 21. Pinion shaft >>G<< 22. Lock pin >>H<< 23. Drive gear >>I<< 24. Side bearing inner race 25. Side bearing outer race 26. Differential side shim 27. Differential case assembly 28. Bearing cap 29. Vent plug 30. Differential cover 31. Packing 32. Drain plug 33. Gasket 34. Filler plug >>J<< · Drive gear backlash adjustment

Reassembly steps 1. Differential carrier 2. Gasket 3. Rear differential lock position switch >>A<< 4. Oil seal >>B<< 5. Drive pinion rear bearing outer race >>C<< 6. Drive pinion front bearing outer race >>D<< · Drive pinion height adjustment 7. Drive pinion 8. Drive pinion rear shim (for adjusting drive pinion height) 9. Drive pinion rear bearing inner race 10. Drive pinion spacer >>E<< · Drive pinion turning torque adjustment 11. Drive pinion front shim (for adjusting preload of drive pinion) 12. Drive pinion assembly 13. Drive pinion front bearing inner race >>E<< 14. Oil seal 15. Companion flange 16. Washer 17. Self-locking nut 18. Gasket 19. Air pipe assembly (B) 20. Eye bolt 21. Air pipe assembly (A) 22. Hose 23. Differential case 24. Side gear spacer 25. Side gear 26. Pinion washer 27. Pinion gear 28. Pinion shaft >>G<< 29. Lock pin >>H<< 30. Drive gear 31. Pressure plate 32. Actuator assembly >>I<< 33. Side bearing inner race 34. Side bearing outer race 35. Differential side shim 36. Bearing cap 37. Vent plug 38. Differential cover 39. Packing 40. Drain plug 41. Gasket 42. Filler plug >>J<< · Drive gear backlash adjustment

Use special tool differential oil seal installer (MB991168) to press-fit the oil seal.

Use the following special tools to press-fit the drive pinion rear bearing outer race. Installer bar (MB990938) Bushing remover and installer base (MB991445)

Use the following special tools to press-fit the drive pinion front bearing outer race. Installer bar (MB990938) Installer adapter (MB990934)

2.Install the following special tools and drive pinion front and rear bearing inner races to the gear carrier as shown in the illustration. Drive pinion gauge attachment (MB991169) <3000> Head (MB991770) <Except 3000> Drive pinion gauge (MB990819)

3.Tighten the nut of special tool a little at a time, while measuring the turning torque of the drive pinion with the following special tools. Then confirm that the turning torque (without the oil seal) is at the standard value. Preload socket (MB990326) Torque wrench (MB990685) Drive pinion gauge assembly (MB990819) Standard value: Bearing division Turning torque N·m New 1.94 - 2.25 4.Clean the side bearing hub.

5.Place the following special tools between the side bearing hub of the gear carrier, and position the notch as shown in the illustration. Then tighten side bearing mounting bolt. Drive pinion gauge attachment (MB991169) <3000> Cylinder gauge (MB991170) <3000> Cylinder gauge (MB991534) <Except 3000> Head (MB991770) <Except 3000> 6.Use a thickness gauge to measure the clearance (A) between special tools. 7.Remove special tools.

8.Use a micrometer to measure the shown dimensions (B, C) of special tools.

9.Install the bearing cap, and then use a cylinder gauge to measure the inside diameter (D) of the bearing cap. 10.Calculate thickness (F) of the required drive pinion rear shim twice by the following formula. Select a shim which most closely matches this thickness. F = A + B + C - 1/2D - 120.00 mm <Except 3000> F = A + B + C - 1/2D - 115.00 mm <3000>

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).

2.Tighten the 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

3.Use the following special tools to measure the drive pinion turning torque (without the oil seal). Standard value: Bearing division Turning torque N·m New 1.94 - 2.25

4.If the drive pinion turning torque is not within the standard value, adjust the turning torque 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 the drive pinion spacer from the following two types. Height of drive pinion spacer mm Identification colour 52.50 Yellow 52.84 Red

5.Remove the companion flange and drive pinion again. Then insert the drive pinion front bearing inner race into the gear carrier. Use special tool differential oil seal installer (MB991168) to press-fit the oil seal.

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 the special tool. Tightening torque: 216 ± 29 N·m

7.Measure the drive pinion turning torque (with oil seal) with special tools 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) 2.03 - 2.34 Gear oil applied 2.10 - 2.40 8.If the turning torque is not within the standard value, check the tightening torque of the companion flange self-locking nut, and the installation of 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 standard value.

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 on both sides.

2.Remove the adhesive adhered to the threaded holes of the drive gear by turning the tap (M10 × 1.25). 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: 152 ± 15 N·m

Use the following special tools to press-fit the side bearing inner races into the differential case. Installer cap (MD998812) Installer adapter (MD998829)

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 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: 74 ± 5 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: 0.13 - 0.18 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 GROUP 26 Front Axle, Differential Carrier Assembly Disassembly).

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.