[27B] REAR AXLE <4WD> - - DIFFERENTIAL CARRIER ASSEMBLY - REASSEMBLY | PRINT PAGE / INDEX / PRIOR / NEXT

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 drive pinion turning torque)
|  | 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. | Differential side bearing inner race
|  | 25. | Differential side bearing outer race
|  | 26. | Differential side bearing spacer
|  | 27. | Differential case assembly
| >>J<< | 28. | Bearing cap
|  | 29. | Vent plug
|  | 30. | Differential cover
|  | 31. | Packing
|  | 32. | Drain plug
|  | 33. | Gasket
|  | 34. | Filler plug
| >>J<< | • | Final drive gear backlash adjustment
LUBRICATION AND ADHESIVE POINTS
| REASSEMBLY SERVICE POINTS
| >>A<< OIL SEAL PRESS-FITTING
| Use the following special tools to press-fit a new oil seal. Installer bar (MB990938) Oil seal installer (MB991115)
| >>B<< DRIVE PINION REAR BEARING OUTER RACE PRESS-FITTING
| Use the following special tools to press-fit the drive pinion rear bearing outer race. Installer bar (MB990938) Installer adapter (MB990935)
| >>C<< DRIVE PINION FRONT BEARING OUTER RACE PRESS-FITTING
| Use the following special tools to press-fit the drive pinion front bearing outer race. Installer bar (MB990938) Installer adapter (MB990932)
| >>D<< DRIVE PINION HEIGHT ADJUSTMENT Adjust the drive pinion height by the following procedures: Apply multipurpose grease to the washer of special tool drive pinion gauge assembly (MB990836).
| Install the special tool, drive pinion front and rear bearing inner races to the differential carrier as shown in the illustration. CAUTION There should be no gear oil adhered to the bearing.
| Tighten the nut of the special tool a little at a time, while measuring the turning torque of the drive pinion by using the following special tools. Then confirm that the turning torque (without the drive pinion oil seal) is at the standard value. Preload socket (MB990326) Torque wrench (MB990685) Standard value:
Bearing division | Turning torque
--- | ---
New | 0.9 - 1.2 N·m
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. Clean the side bearing seat of the differential carrier and bearing caps.
| Place the following special tools in the side bearing seat of the differential carrier, and position the notch as shown in the illustration. Then install the bearing caps. Cylinder gauge (MB990392) Drive pinion gauge assembly (MB990836) Use a thickness gauge to measure the clearance (A) between special tools. Remove the bearing caps and special tools.
| Use a micrometer to measure the shown dimensions (B, C) of special tools.
| Install the bearing cap, and then use a cylinder gauge to measure the inside diameter (D) of the bearing cap. Calculate thickness (F) of the required drive pinion rear shim by the following formula. Select a shim which most closely matches this thickness. F = A + B + C - 1/2D - 86.00 mm
| 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 (MB990728).
| >>E<< DRIVE PINION TURNING TORQUE ADJUSTMENT/OIL SEAL INSTALLATION Adjust the drive pinion turning torque by the following procedures: Insert the drive pinion into the differential carrier, and then install the following parts in sequence from the carrier rear side: drive pinion spacer, drive pinion front shim , drive pinion front bearing inner race and companion flange. NOTE: Do not install the oil seal.
| Tighten the companion flange self-locking nut to the specified torque while holding the companion flange with special tool end yoke holder (MB990850). Tightening torque: 186 ± 29 N·m CAUTION There should be no gear oil adhered to the bearing.
| Use following special tools MB990685 and MB990326 to measure the drive pinion turning torque (without the drive pinion oil seal). Preload socket (MB990326) Torque wrench (MB990685) Standard value:
Bearing division | Turning torque
--- | ---
New | 0.9 - 1.2 N·m
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. Select the drive pinion spacer from the following two types.
Height of drive pinion spacer (A) mm | Identification colour
--- | ---
57.08 | Red
57.72 | -
| Remove the companion flange and drive pinion again. Then insert the drive pinion front bearing inner race into the differential carrier. Use special tool oil seal installer (MB990031 or MB990699) to press-fit the drive pinion oil seal.
| 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: 186 ± 29 N·m
| Use 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. Standard value:
Bearing division | Companion flange lubrication | Turning torque
--- | --- | ---
New | None (with anti-rust agent) | 1.0 - 1.3 N·m
Gear oil applied | 0.5 - 0.6 N·m
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.
| >>F<< DIFFERENTIAL GEAR BACKLASH ADJUSTMENT Adjust the differential gear backlash by the following procedure:
| Assemble the side gears, side gear spacers, pinion gears, and pinion washers into the differential case. Temporarily install the pinion shaft. NOTE: Do not assemble the lock pin yet.
| Insert a wedge between the side gear and the pinion shaft to lock the side gear. While locking the side gear with the wedge, measure the differential gear backlash with a dial indicator on the pinion gear. Measure by the same procedure for the other pinion gear. Standard value: 0 - 0.076 mm Limit: 0.2 mm If the backlash exceeds the limit value, adjust it by replacing the side gear spacers. If adjustment is not possible, replace the side gears and pinion gears as a set. Check that the backlash is within the limit value and that the differential gear turns smoothly.
| >>G<< LOCK PIN INSTALLATION Align the pinion shaft lock pin hole with the differential case lock pin hole, and drive in the lock pin.
| Stake the lock pin with a punch on both sides.
| >>H<< DRIVE GEAR INSTALLATION Clean the drive gear attaching bolts.
| Remove the adhesive adhered to the threaded holes of the drive gear by turning the tap (M10 x 1.25). Clean the threaded holes by applying compressed air.
| Apply the specified sealant to the threaded holes of the drive gear. Specified sealant: 3M stud locking 4170 or equivalent Install the drive gear onto the differential case with the mating marks properly aligned. Tighten the drive gear attaching bolts to the specified torque in a diagonal sequence. Tightening torque: 84 ± 4 N·m
| >>I<< DIFFERENTIAL SIDE BEARING INNER RACE INSTALLATION
| Use special tool bearing installer (MB990728) to press-fit the differential side bearing inner races into the differential case.
| >>J<< BEARING CAP INSTALLATION/FINAL DRIVE GEAR BACKLASH ADJUSTMENT Adjust the final drive gear backlash by the following procedure: Assemble the differential case with the side bearing outer race to the differential carrier.
| Press the differential case to one side to measure the clearance of the side bearing outer race and the differential carrier. Select two pairs of side bearing spacers. Determine the thickness by adding 1/2 of the clearance to the pre-load 0.05mm.
| Remove the side bearing by using special tool side bearing puller (MB990810). NOTE: Hook the claws of the special tool with the side bearing inner race by using the notches (two areas) of the differential case side. Assemble the selected side bearing spacers to each side.
| Use special tool bearing installer (MB990728) to press-fit the side bearing inner race into the differential case. After installing the outer race, assemble the differential case to the differential carrier. Align the mating marks of differential carrier and the bearing cap with each other and tighten the bearing cap attaching bolts to the specified torque. Tightening torque: 37 ± 2 N·m
| Measure the final drive gear backlash at four points or more on the circumference of the drive gear. Standard value: 0.11 - 0.16 mm
| If the backlash is not within the standard value, move the side bearing spacer as shown in the illustration to adjust the backlash. NOTE: The increment of side bearing spacer must be the same as the decreased amount. Inspect the tooth condition at the final drive gear and replace if required. (Refer to .)
| Measure the drive gear runout. Limit: 0.05 mm If drive gear runout exceeds the limit, remove the differential case and then the drive gears, moving them to different positions and reinstall them. If adjustment is not possible, replace the differential case or drive gear and drive pinion as a set.

[27B] REAR AXLE <4WD> - - DIFFERENTIAL CARRIER ASSEMBLY - REASSEMBLY | PRINT PAGE / INDEX / PRIOR / NEXT

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