PROPELLER SHAFT &

DIFFERENTIAL CARRIER

SECTION PD
CONTENTS
PREPARATION ................ . ···················. 3 Searl ng ...................................................................24 i'~
Special Service Tools .. . ... 3 ADJUSTMENT...... ... ... . . ...... ... .................. 25
Side Bearing Preload ............................................ 25
Propeller shalt Pinion Gear Height and Pinion Bearing ©ll
Preload .................. . .... 26
PROPELLER SHAFT ........ . ·················· 8 Tooth Contact.. ....................................... . ...... 30 iill'if
On-vehicle Service ... . ............. 10
ASSEMBLY ...................................... .. ............. 31
Removal and Installation ....... 10
Extension Tube and Differential Side Shaft .......... 31
Inspection. .. 10
Differential Case ..................................... . . .. 31 ffi\11
Disassembly ...... . .11
Final Drive Housing. ... 32
Assembly ............................................................... 12

R200A
Final drive
FRONT FINAL DRIVE ..... .......... 36
ON-VEHICLE SERVICE .............................................. 14
DISASSEMBLY .... ........... 37
Front Oil Seal Replacement (Front final drive) .... 14
Pre-inspection ............. . ........................ 37
Front Oil Seal Replacement .... .... 14
Final Drive Housing ... ..... 37
Rear Cover Gasket Replacement. .15
Differential Case ............ . .. .40 I"I'\
REMOVAL AND INSTALLATION
Differential Side Shaft............ ............. ..40
(Front final drive) .... . . ... ············ ..... 16
INSPECTION................................................... ..42
Removal ........... . .................. 16
Ring Gear and Drive Pinion .... . ... .42
Installation ....................... . ...... 16
Difterential Case Assembly ............ . ............. .42
REMOVAL AND INSTALLATION
Bearing ............................................................... 42 !BJI'l
(Rear final drive) .. ············· ............. 17
ADJUSTMENT ............................................................ .43
Removal .. .................................................. 17
Side Bearing Preload ........................................... 43
Installation ............................................................. 17
Pinion Gear Height and Pinion Bearing
Preload ....................... . .... ········· .44
R180A
Tooth Contact.. ..................................................... .49
FRONT FINAL DRIVE.. . ................................. 18 ASSEMBLY ..................................................................50 ~[F

DISASSEMBLY ....................................................... 19 Differential Side Shaft.. ............................... 50

Pre-inspection ............... . . .................... 19 Differential Case ........ ............ . ............. 51
Final Drive Housing .............. . ..... 19 Final Drive Housing .............................................. 52
Differential Case. ..... 21
Extension Tube and Differential Side Shaft.. .22 H190A
INSPECTION .................................... .24
REAR FINAL DRIVE ........... 56
Ring Gear and Drive Pinion ................................. 24
DISASSEMBLY ....... 57 ~[jj[
Differential Case Assembly ......... 24
Pre-inspection ...... . ............... 57
799
 CONTENTS <cont'd.)

Differential Carrier ............ ,. ...... . .57 INSPECTION ............................................................... 79

Differential Case ..... . ············ .. 59 Ring Gear and Drive Pinion ................................... 79
INSPECTION ................................ . .61 Differential Case Assembly.. ....................... 79
Ring Gear and Drive Pinion .. . .. 61 Bearing .............. . ................. 79
Differential Case Assembly .. . 61 LIMITED SLIP DIFFERENTIAL ... ... 80
Bearing ............................................ . ....... 61 Preparation for Disassembly ... .. ... 80
ADJUSTMENT ..................................... . ........... 62 Disassembly .................................... . ..... 80
Side Bearing Preload ... ............................... 62 Inspection ................................................................ 81
Pinion Gear Height ... ,. .. 63 Adjustment ................. ..................................... 82
Tooth Contact... ............ . ... 67 Assembly ............ . ..... 83
ASSEMBLY ................................. . .... 68 ADJUSTMENT ...... . ..... 86
Differential Case ,. ............................ . ..... 68 Pinion Bearing Preload and Pinion Gear
Differential Carrier .............. ,.. ..... 69 Height ................................................... . ..... 86
Tooth Contact ....................................................... 90
H233B ASSEMBLY ........... .................................... ..... 91
Differential Case- 2-pinion type- ..... .......... 91
REAR FINAL DRIVE ......... . ......... 73
Differential Case- 4-pinion type-. ...... 92
DISASSEMBLY ............... . ........ 75
Differential Carrier ........................... . .............. 93
Pre-inspection ........ . ........................ 75
SERVICE DATA AND SPECIFICATIONS (SDS) .......... 96
Differential Carrier ..... . ................................ 75
Propeller Shaft ... 96
Differential Case .......... . ....... 77
Final Drive .............. . ..... 98

800
 PREPARATION

Special Service Tools

Tool number Unit application
(Kent-Moore No.) Description
Tool name R180A R200A H190A H233B

ST3217SOOO Measuring pinion bearing

(See J25785-A) preload and total preload
Preload gauge
(!) GG91030000 JD
(J25765)
CD- ~ qg=o
Torque wrench
@ HT62940000
®------{i X X X X

( - I
Socket adapter ~
@ HT62900000
( - I
Socket adapter NT124

KV38100800 a Mounting final drive

~
( - ) (To use, make a new hole.)
Differential attachment a: 152 mm (5.98 In) X X - -
Equivalent tool 0

=:re
(J25604-011 NT119

ST06310000 Mounting final drive

( - I
Differential attachment - - X -
Equivalent tool
(J25602-011
NT140

JY
ST06340000 Mounting final drive
( - I
Differential attachment - - - X
Equivalent tool
(J243101
NT140

ST32580000 Adjusting side bearing pre-

(J343121 load and backlash (ring
Differential side bearing gear-drive pinion) - - - X
adjusting nut wrench

NT141

ST33290001 Removing side bearing

~
(J25810-A) outer race and side oil seal
Side bearing outer race X - - -
puller

NT076

ST38060002 Removing and installing

~
(J343111 propeller shaft lock nut,
Drive pinion flange and drive pinion lock nut X X X -
wrench

NT113

KV38104700 Removing and installing

~
(J343111 propeller shaft lock nut,
Drive pinion flange and drive pinion lock nut - - - X
wrench
ll'IL

NT113

PD-3 801
 PREPARATION
Special Service Tools (Cont'd)
Tool number Unit application
(Kent-Moore No.) Description
Tool name R180A R200A H190A H233B

ST3090SOOO Removing and instatring

I ) drive pinion rear inner
Drive pinion rear inner cone
race puller set
(j) ST30031000
IJ22912-01)
X X X X
Puller
@ ST30901000
I )
Base
Equivalent tool
IJ26010-01)
ST3306S001 Removing and installing
Differential side bearing differential side bearing
puller set inner cone
(j) ST33051001
I )
Body X X X X
Equivalent tool
IJ22888)
@ ST33061000
IJ8107-2)
Adapter
ST33230000 Installing side bearing
IJ25805-01) inner cone
Differential side bearing a: 51 mm (2.01 In) dla.
X X
drift b: 41 mm (1.61 In) dia.
c: 28.5 mm (1.122 in) dia.

KV38100300 Installing side bearing

IJ25523) inner cone
Differential side bearing a: 54 mm (2.13 in) dla.
X
drift b: 46 mm (1.81 In) dia.
c: 32 mm (1.26 In) dla.

ST33190000 Installing side bearing

I ) inner cone
Differential side bearing a: 52 mm (2.05 In) dla.
X
drift b: 45.5 mm {1.791 In) dla.
Equivalent tool c: 34 mm (1.34 in) dia.
IJ25523)
ST33081000 Installing side bearing
I ) inner cone
Side bearing puller
X
adapter

NT137

PD-4 802
 PREPARATION
Special Service Tools (Cont'd)
Tool number Unit application
(Kent-Moore No.) Description
Tool name R1BOA R200A H190A H233B

KV38100600 Installing side bearing

~
IJ25267I spacer
Side bearing spacer - X - -
drift
liilfi\
NT123

ST30611000 Installing pinion rear

IJ25742-1I bearing outer race
Drift X X X X

~
NT090

ST30621000 Installing pinion rear bear-

~
IJ25742-51 ing outer race
Drift a: 79 mm {3.11 in) dia. X X X X
b: 59 mm {2.32 In) dla.
a
NT073

ST30701000 Installing pinion front bear-

~
(J25742-21 ing outer race
Drift a: 61.5 mm (2.421 in) dia, X - - -
b: 41 mm (1.61 in) dia.

NT073

ST30613000 Installing pinion front bear-

~
IJ25742-31 ing outer race
Drift a: 72 mm (2.83 in) dla. - X X X
b: 48 mm (1.89 in) dia.

NT073

KV381025SO Installing front oil seal

I - I
Oil seal fitting tool
CD

®~
ST30720000
I - I
Drift bar X - X X
Equivalent tool
IJ254051
® KV38102510
I - I
Drift NT122
KV38100500 Installing front oil seal
-
r(£?
I I
Gear carrier front oil
seal drift
- X - -
Equivalent tool
(J252731 NT121

ST33720000 Installing side retainer

(J258171
Differential side retainer
guide
v~ X - - -

NT138

PD-5 803
 PREPARATION
Special Service Tools (Cont'd)
Toot number Unit application
(Kent-Moore No.) Description
Tool name R180A R200A H190A H233B

ST33270000 Installing side oil seal

~
(J25809)
Side oil seal drift X - - -

NT139

KV38100200 Installing side oil seal

~
(J26233)
Gear carrier side oil - X - -
seal drift

NT120

(J34309) Adjusting bearing pre-load

0
Differential shim and gear height
selector

~
0~?-$
~0~
X X X X

NT134

(J25269-4) Selecting pinion height

Side bearing discs
(2 Req'd) @ adjusting washer
X X - -

NT136

(J25269-18) Selecting pinion height

Side bearing discs
(2 Req'd)
@ adjusting washer
- - X X

NT135

(J8129)
~
Spring gauge

<5'
~ Measuring carrier turning
X X X X

NT127 torque

(J35764) Installing side oil seal

~
Gear carrier side oil
seal drift X - - -

NT120

PD-6 804
 PREPARATION
Special Service Tools (Cont'd)
Tool number Unit application
(Kent-Moore No.) Description
Tool name R180A R200A H190A H2338

KV381051SO Checking differential torque

I - ) on limited slip differential

~ ~
Rear axle shaft dummy
G) KV38105110
I - ) - - X -
Torque wrench side
@ KV38105120
I - )
Vice side NT142

KV381052SO Checking differential torque

I - ) on limited slip differential
Rear axle shaft dummy

~ ~
G) KV38105210
I - ) - - - X
Torque wrench side
@ KV38105220
I - )
Vice side NT142

PD-7 805
 PROPELLER SHAFT

Front propeller shaft (Model 2F71 H)

~39-44
(4.0 - 4.5, 29 - 33)

\Flange yoke
!ropeller
\ shaft tube

~
\v~
%)
r~m·~--~
lsnap ring* ~
*:
\_~ 39 - 44 (4.0 - 4.5, 29 - 33) Adjustment is required.
~: N•m (kg-m, ft·lb)

SPD724

Rear propeller shaft (Model 25808)

Propeller shaft tube

Snap ring*~

~78-88
(8-9,58-65)

*: Adjustment is required.
~: N·m (kg-m. ft-lb)

SPD250A

PD-8 806
 PROPELLER SHAFT

Rear propeller shaft (Model 35808)

Washer
Apply a coat of multi-purpose lithium grease
containing molybdenum disulfide to the end
face of the center bearing and both sides of
the washer.

Center bearing upper

mounting bracket
Propeller shaft
2nd tube

<JP"_.J
'
-1/ L--- ®

\~78- 88
(8-9,58-65)
~78-88
(8-9,58-65)

~: N•m (kg-m, ft-lb)

* : Adjustment is required.
SPD287A jk'jj'
Rear propeller shaft (Model 3571A)

Washer
Apply a coat of multi-purpose
lithium grease containing
molybdenum disulfide to the
end face of the center bearing
and both sides of the washer.
Center bearing upper
mounting bracket
Propeller shaft
2nd tube
\Lock nut

-: '!'
\~245- 294 . v
~16- 22 ~25 - 30, 181 - 217)
i (1.6 - 2.2, <P"__)
J 12 - 16)

~~/
~39-44_)
(4.0 - 4.5, 29 - 33)

\ \Companion flange

"'\~ 39- 44 (4.0- 4.5, 29- 33)

I Center bearing assembly

~Propeller shaft
1st tube Center bearing lower mounting bracket

~: N•m (kg-m, ft-lb)

SPD288A ~[i)j:\

PD-9 807
 PROPELLER SHAFT

On-vehicle Service
PROPELLER SHAFT VIBRATION
If vibration is present at high speed, inspect propeller shaft
runout first.
1. Raise rear wheels.
2. Measure propeller shaft runout at several points by rotat-
ing final drive companion flange with hands.
3. If runout exceeds specifications, disconnect propeller shaft
at final drive companion flange; then rotate companion
flange 180 degrees and reconnect propeller shaft.
Runout limit: 0.6 mm (0.024 in)
4. Check runout again. If runout still exceeds specifications,
replace propeller shaft assembly.
5. Perform road test.
APPEARANCE CHECKING
• Inspect propeller shaft tube surface for dents or cracks.
If damaged, replace propeller shaft assembly.
• If center bearing is noisy or damaged, replace center bear-
ing.

Removal and Installation

• Put match marks on flanges and separate propeller shaft
from final drive.

• Draw out propeller shaft from transmission and plug up

Transmission rear end of transmission rear extension housing.

Plug
SPD359

Inspection
• Inspect propeller shaft runout. If runout exceeds
specifications, replace propeller shaft assembly.
Runout limit: 0.6 mm (0.024 in)

SPD106

PD-10 808
 PROPELLER SHAFT
Inspection (Cont'd)
• Inspect journal axial play .
If the play exceeds specifications, replace propeller shaft
assembly.
Journal axial play:
0.02 mm (0.0008 in) or less
@I.

SPD874

Disassembly
CENTER BEARING
1. Put match marks on flanges, and separate 2nd tube from
1st tube.

!'ll1f

SPD110

3. Remove locking nut with Tool.

Tool number:
R180A, R200A, H190A
ST38060002 (J34311)
H233B
KV38104700 (J34311)
4. Remove companion flange with puller.

~ SPD170A

5. Remove center bearing with Tool and press.

Tool number: ST30031000 (J22912-01)

SPD113

PD-11 809
 PROPELLER SHAFT
Disassembly (Cont'd)
JOURNAL (71H and BOB)
71H: Do not disassemble.
1. Put match marks on shaft and flange or yoke.

SPDl28

2. Remove snap ring.

3. Remove pushed out journal bearing by lightly tapping yoke

with a hammer, taking care not to damage journal and yoke
hole.

SPD732

4. Remove bearing at opposite side in above operation.

Put marks on disassembled parts so that they can be rein-
stalled in their original positions from which they were
removed.

SPD131

Assembly
CENTER BEARING
• When installing center bearing, position the "F" mark on
center bearing toward front of vehicle.
• Apply a coal of multi-purpose lithium grease containing
molybdenum disulfide to the end face of the center bearing
and both sides of the washer.

SPD114

PD-12 810
 PROPELLER SHAFT
Assembly (Cont'd)
• Stake the nut. Always use new one.
• Align match marks when assembling tubes.

JOURNAL (71 H and BOB)

1. Assemble journal bearing. Apply recommended multi-pur- l~
pose grease on bearing inner surface.
When assembling, be careful that needle bearing does not fall
down.

2. Select snap ring that will provide specified play in axial

direction of journal, and install them.
Refer to SDS (PD-97).
Select snap rings with a difference in thickness at both sides
within 0.06 mm (0.0024 in).

3. Adjust thrust clearance between bearing and snap ring to

zero by tapping yoke.

4. Check to see that journal moves smoothly and check for

axial play.
Axial play: 0.02 mm (0.0008 in) or less

SPD874

PD-13 811
 ON-VEHICLE SERVICE I Final drive I

Front Oil Seal Replacement (Front final drive)

1. Remove front propeller shaft.
2. Loosen drive pinion nut.
Tool number: ST38060002 (J34311)

3. Remove companion flange.

SP0734

4. Remove front oil seal.

5. Apply multi-purpose grease to cavity at sealing lips of oil

seal. Press front oil seal into carrier.
6. Install companion flange and drive pinion nut.
7. Install propeller shaft.
Tool number:
R180A
ST30720000 ( )
Equivalent tool (J25405)
R200A
KV381 00500 ( )
Equivalent tool (J25273)

Front Oil Seal Replacement

CAUTION:
For final drive models using collapsible spacer (H190A) bear-
ing preload must be adjusted whenever companion flange is
removed. Therefore, final drive overhaul is required.
1. Remove propeller shaft.
2. Loosen drive pinion nut.
Tool number: KV38104700 (J34311)

PD237

PD-14 812
 ON-VEHICLE SERVICE I Final drive I
Front Oil Seal Replacement (Cont'd)
3. Remove companion flange.

4. Remove front oil seal.

SPD738

5. Apply multi-purpose grease to cavity at sealing lips of oil

seal. Press front oil seal into carrier.
~I "if
Tool number: (J25273)
6. Install companion flange and drive pinion nut.
7. Install rear propeller shaft.

SPD739

Rear Cover Gasket Replacement

1. Drain gear oil.
2. Remove rear cover and rear cover gasket.
3. Install new rear cover gasket and rear cover.
4. Fill final drive with recommended gear oil.

SPD740-A

PD-15 813
 REMOVAL AND INSTALLATION {Front final drive) I Final drive I

Removal
1. Remove front propeller shaft.
2. Remove drive shaft. Refer to "FRONT AXLE (4WD)" in FA
section.
3. Remove engine mounting bolts and raise up engine.
4. Remove front final drive together with differential mounting
member.

Installation
1. Install front final drive assembly together with differential
mounting member.

2. Perform tightening front final drive securing bolts and nuts

by following procedure to prevent drive train vibration.
(1) Temporarily tighten nut ®.
(2) Temporarily tighten nut CID.
(3) Tighten bolt © to the torque of 68 to 87 N·m (6.9 to 8.9
kg-m, 50 to 64 ft-lb).
(4) Tighten bolt ® to the torque of 68 to 87 N·m (6.9 to 8.9
kg-m, 50 to 64 ft-lb).
(5) Tighten nut ® to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m,
front
50 to 64 ft-lb).
¢' (6) Tighten nut CID to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m,
.'f,;: 50 to 64 ft-lb) .
(7) Tighten nut ® to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
3. Install drive shaft. Refer to "FRONT AXLE (4WD)" in FA
section.
4. Install front propeller shaft.

SPD743

PD-16 814
REMOVAL AND INSTALLATION (Rear final drive) I Final drive I

Removal
• Remove propeller shaft.
Plug front end of transfer.
• Remove axle shaft.
Refer to '"REAR AXLE" in RA section. @[:
CAUTION:
• Be careful not to damage spline, sleeve yoke and front oil
seal when removing propeller shall.
• Before removing the final drive assembly or rear axle
assembly, disconnect the ABS sensor harness connector
from the assembly and move II away from the final drive/
rear axle assembly area. Failure to do so may result in the
sensor wires being damaged and the sensor becoming ll\:
inoperative.

Installation
• Fill final drive with recommended gear oil.

SPD123

• Pay attention to the direction of gasket (H233B only).

PD-17 815
 l
l\
tr : Adjustment is required. Pinion mate shaft
* Using locking agent {Locktite (stud lock) or equivalent]
~: N•m (kg-m, ft-lb) Side flange l:~ut
~: Apply recommended sealant (Nissan genuine
part: KP610-00250) or equivalent

~ 31 • 42 (3.2 • 4.3, 23 • 31)

O-ring ~
""-~ ,_ .~~~1~ Pinion mate gear~
((O.
_
®
~

Rear cover
Pinion mate thrust washer ~~
r
t1·
~ Dffferentral case LH
Drive pinion
"A\~,o ~69-78(7·8,51·58)
@@ .,
'"'"'"I " :tl
' ' "-1I' 0

,c
.

Rrng gear
'

""""'/
"

l":i1v
~Inner cone
L .
....z
<::: ___. * l{(!J} Srde bearing !!
...•
1
z
co .ttng sh1m-& l>
r
c
~~
I
~
v -~
retamer

J
(}or:. Grease
•

seal~
Rear axle beanng spacer
:tl
<
m

0-nng~....J J
Side retainer adjusting shim tt
S1de retamer
J 1':7~ ~
~

<
~

6ff)J)
0
~

Front oil

Companion flange
seal~

167 _ 196 (17 _ 20, 123 • 145)

~ 9- 12 (0.9 • 1.2, 6.5 - 8.7}----'

~ 88 - 98 {9.0 - 10.0, 65 - 72)_)

Extensron tube assembly
-~
1@: W
L
'::....§

Differential side shaft

~ 34 • 44 (3.5 • 4.5. 25 - 33)

"'
~

~ 00
816
 DISASSEMBLY I R180A I

Pre-inspection
Before disassembling final drive, perform the following inspec-
tion.
• Total preload
1) Turn drive pinion in both directions several times to set @~
bearing rollers.
2) Check total preload with Tool.
Tool number: ST3127SOOO (J25765-A)
Total preload:
1.2- 2.3 N·m
(12 - 23 kg-em, 10 - 20 in-lb)
• Ring gear to drive pinion backlash
Check backlash of ring gear with a dial indicator at several
points. lil:
Ring gear to drive pinion backlash:
0.13- 0.18 mm (0.0051 - 0.0071 in)

SP0635

• Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit:
0.05 mm (0.0020 in)
• Tooth contact
Check tooth contact. Refer to ADJUSTMENT (PD-30).

Final Drive Housing

1. Using three spacers [20 mm (0.79 in)], mount final drive IC!l\
assembly on Tool.
Tool number:
KV381 00800 ( ) IR!l\
Equivalent tool (J3431 0), (J25604)

Tool
SPD637

2. Remove extension tube and differential side shaft assem-

bly.

SPD638

PD-19 817
 DISASSEMBLY I R180A I
Final Drive Housing (Cont'd)
3. Remove differential side flange.

4. Mark side retainers for identification. Remove side retain-

ers.
Be careful not to confuse right and left side retainers and
shims.

5. Extract differential case from final drive housing.

6. Remove side outer races.

Tool number: ST33290001 (J25810-A)
Be careful to keep the side bearing outer races together with
their respective inner cones - do not mix them up.
7. Remove side oil seal.

8. Loosen drive pinion nut.

Tool number: ST38060002 (J34311)
9. Remove companion flange with puller.

PD-20 818
 DISASSEMBLY I R180A I
Final Drive Housing (Cont'd)
10. Take out drive pinion together with p1mon rear bearing
inner cone, drive pinion bearing spacer and pinion bearing
adjusting washer.
11. Remove front oil seal and pinion front bearing inner cone.

12. Remove pm1on front and rear bearing outer races with
brass drift.

13. Remove pinion rear bearing inner cone and drive pinion
adjusting washer.
Tool number: ST30031000 (J22912-01)

;~'ii'

Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws In grooves.
Tool number:
® ST33051 001 ( )
Equivalent tool (J22888)
@ ST33061000 (J8107-2)
Tool @

• Shows groove

SPD642

PD-21 819
 DISASSEMBLY I R180A I
Differential Case (Cont'd)
Be careful not to confuse the right and left hand parts.

SPD022

2. Loosen ring gear bolts in a criss-cross fashion.

3. Tap ring gear off differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

4. Separate differential case LH and RH.

Put match marks on both differential case LH and RH sides
prior to separating them.

Extension Tube and Differential Side Shaft

1. Remove differential side shaft assembly from extension
tube.

2. Cut rear axle bearing collar with cold chisel. Be careful not
to damage differential side shaft.

PD-22 820
 DISASSEMBLY I R180A I
Extension Tube and Differential Side Shaft
(Cont'd)
3. Reinstall differential side shaft into extension tube and
secure with bolts. Remove rear axle bearing by drawing out
differential side shaft from rear axle bearing with puller.
(j]~

Without collar
)II]&\

~re:ll¥1l

Lrc:

~IF@
~(!::;

[p~

SP0646
!I::L
4. Remove grease seal.

1~1

&\11

'Iii'

SPD647

.'!'&\

~&

~lFJ

\'i)'[j

~IP

~ffi\

~IL

[~};(

PD-23 821
 INSPECTION I R180A I

Ring Gear and Drive Pinion

Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive
pinion as a set (hypoid gear set).

Differential Case Assembly

Check mating surfaces of differential case, side gears, pinion
mate gears, pinion mate shaft and thrust washers.

SPD648

Bearing
1. Thoroughly clean bearing.
2. Check bearing for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If
damaged, replace outer race and inner cone as a set.

SP0715

PD-24 822
 ADJUSTMENT I R180A I

For quiet and reliable final drive operation, the following five
adjustments must be made correctly:
1. Side bearing preload.
2. Pinion gear height.
3. Pinion bearing preload.
4. Ring gear to pinion backlash. Refer to ASSEMBLY (PD-34). ·~~
5. Ring and pinion gear tooth contact pattern.

Side Bearing Preload

Note: A selection of carrier side retainer adjusting shims is '"!:
required lor successful completion of this procedure.
1. Make sure all parts are clean and that the bearings are well
rEIF@
lubricated with light oil or Dexron type automatic transmis- li'"'
sion fluid. "'""
2. Install differential carrier and side bearing assembly into
the final drive housing.

3. Place all of the original side retainer adjusting shims onto

the side bearing retainer that goes at the ring gear end of
the carrier.

SPD192A

4. Install both bearing retainers onto the final drive housing

and torque the retainer bolts.
Boll torque specification:
9- 12 N·m (0.9- 1.2 kg-m, 6.5- 8.7 11-lb)

5. Turn the carrier several times to seat the bearings.

6. Measure the carrier turning torque with a spring gauge, [ijp
J8129, at the ring gear retainer bolt. elF
Turning torque specification:
34.3 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb)
of pulling Ioree at the ring gear bolt.

PD-25 823
 ADJUSTMENT I R180A I
Side Bearing Preload (Cont'd)
7. If the turning torque measured is incorrect, establish the
correct bearing preload by adding to or subtracting from
the total amount of shim thickness.
• Increase shim thickness to decrease turning torque on the
carrier.
• Decrease shim thickness to increase turning torque on the
carrier.

8. Record the correct, selected total thickness of the side

retainer adjusting shims, and remove the carrier and bear-
ings from the final drive housing. Save all shims for later
re-use.

SP0195A

Pinion Gear Height and Pinion Bearing Preload

1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion gear bearings into the pi.nion pre-load
shim selector tool, J34309.
• Front Pinion Bearing- make sure the J34309-3 front pin-
ion bearing seat is secured tightly against the J34309-2
11111111111111111 rJ gauge anvil. Then turn the front pinion bearing pilot,
J34309-7, to secure the bearing in its proper position.

SPD769

• Rear Pinion Bearing - the rear pm1on bearing pilot,

J34309-8, is used to center the rear pinion bearing only. The
rear pinion bearing locking seat, J34309-4, is used to lock
the bearing to the assembly.

SPD196A

SPD197A

PD-26 824
 ADJUSTMENT I R180A I
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
3. Place the pinion preload shim selector tool gauge screw,
J34309-1, with the pinion rear bearing inner cone installed,
into the final drive housing.

4. Install the J34309-2 gauge anvil with the front pinion bear-
ing into the final drive housing and assemble it to the '"!:
J34309-1 gauge screw. Make sure that the J34309-16 gauge
plate will turn a full 360 degrees, and tighten the two sec-
tions by hand. !ElF@
li':!:

~- ~
~=============~ 5. Turn the assembly several times to seat the bearings.

SPD770

6. Measure the turning torque at the end of the J34309-2 shalt

using torque wrench J25765-A. :f'IA
Turning torque specification:
0.6- 1.0 N·m (6- 10 kg-em, 5.2- 8.7 in-lb)
7. Place the J34309-10 "R180A" pinion height adapter onto the l:liA
gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

PINION BEARING PRELOAD WASHER SELECTION

8. Place the solid pinion bearing adjusting spacer squarely [ijfF
into the recessed portion of the J34309-2 gauge anvil.

PD-27 825
 ADJUSTMENT I R180A I
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
9. Select the correct thickness of pinion bearing preload
adjusting washer using a standard gauge of 6 mm (0.24 in)
and your J34309-1 01 feeler gauge. The exact total measure
you get with the gauges is the thickness of the adjusting
washer required. Select the correct washer.
·Drive pinion bearing adjusting washer:
Refer to SDS (PD-99).
10. Set your selected, correct pinion bearing preload adjusting
washer aside for use when assembling the pinion and
bearings into the final drive housing.
PINION HEIGHT ADJUSTING WASHER SELECTION
11. Position the side bearing discs, J25269-4, and arbor firmly
into the side bearing bores.

12. Select the correct standard pinion height adjusting washer

thickness using a standard gauge of 3 mm (0.12 in) and
your J34309-1 01 feeler gauge. Measure the distance
between the J34309-10 "R180A"" pinion height adapter and
the arbor.

13. Write down your exact total measurement.

PD-28 826
 ADJUSTMENT I R180A I
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
14. Correct the pinion height washer size by referring to the
"pinion head number".
Note: There are two numbers painted on the pinion gear. The
first one refers to the pinion and ring gear as a matched !ll~
set and should be the same as the number on the ring
gear. The second number is the "pinion head height
number", and it refers to the ideal pinion height from llll/\1
standard for quietest operation. Use the following chart to
determine the correct pinion height washer.
SPD542
Add or Remove from the Standard
Pinion Head Height Number Pinion Height 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) )ll]'j'

+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)

15. Select the correct p;mon height washer.
Drive pinion height adjusting washer:
Refer to SDS (PD-99).

16. Remove the J34309 pinion preload shim selector tool from
the final drive housing and disassemble to retrieve the ~IS
pinion bearings.

SPD205A

PD-29 827
 ADJUSTMENT R180A

Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gear sets which are not positioned properly in relation
to one another may be noisy, or have short life, or both. With a
pattern check, the most desirable contact for low noise level
and long life can be assured.

1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered ferric oxide and oil
or equivalent to 3 or 4 teeth of ring gear drive side.

SPD357

3. Hold companion flange steady by hand and rotate the ring

gear in both directions.

Usually the pattern will be correct If you have calculated the shims correctly and the backlash Is correct.
However, In rare cases you may have to use trial-and-error processes until you get a good tooth contact pattern.
The tooth pattern Is the best Indication of how well a differential has been set up.

Heel contact Face contact Toe contact Flank contact

~~
To correct, increase thickness of pinion
height adjusting washer in order to bring
To correct, reduce thickness of pinion
height adjusting washer in order to make
drive pinion close to ring gear. drive pinion go away from ring gear.

-·~-/V--h
When adjustment Is completed, be sure to wipe
off completely the ferric oxide and oil or their
equivalent
~
~ SPD007

PD-30 828
 ASSEMBLY I R180A I

\Bearing Extension Tube and Differential Side Shaft

~~-~..::
1. Measure rear axle bearing end play.
Rear axle bearing end play (A - B):
0.1 mm (0.0039 in) or less
The end play can be adjusted with bearing adjusting shim. @[
Available bearing adjusting shims:

~--·r·
Refer to SDS (PD-99).

SPD206A

2. Install grease seal.

Tool number: (J35764)

Tool

SPD654

•
Press 3. Install extension tube retainer, rear axle bearing and rear
Tool axle shaft bearing collar on differential side shaft.
4. Install differential side shaft assembly into extension tube.

SPD655

Differential Case
1. Measure clearance between side gear thrust washer and I'll\
differential case.
s Clearance between side gear thrust washer
and differential case (A - B): illffi\
0.10- 0.20 mm (0.0039- 0.0079 in)
The clearance can be adjusted with side gear thrust
washer. !831'1
Available side gear thrust washers:
Refer to SDS (PD-99).
2. Apply gear oil to gear tooth surfaces and thrust surfaces ~1
and check to see they turn properly.

SPD656

PD-31 829
 ASSEMBLY I R180A I
Differential Case (Cont'd)
3. Install differential case LH and RH.

4. Place differential case on ring gear.

5. Apply locking agent [Locktite (stud lock) or equivalent] to
ring gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.

SPD746

6. Press-fit side bearing inner cones on differential case with

Tool.
Tool number:
Tool@
® ST33230000 (J25805-01)
<ID ST33061 000 (J81 07-2)

PD353

Final Drive Housing

1. Press-fit front and rear bearing outer races with Tools.
Pinion rear A Tool number:
bearing outer~';•c:e~fl?=l ® ST30611000 (J25742-1)
<ID ST30621000 (J25742-5)
© ST30701000 (J25742-2)

Pinion front
bearing outer race

SPD679

PD-32 830
 ASSEMBLY I R180A I
Final Drive Housing (Cont'd)
2. Select pinion bearing adjusting washer and drive pinion
bearing spacer. Refer to ADJUSTMENT (PD-26).
3. Install drive pinion height adjusting washer in drive pinion,
and press-fit pinion rear bearing inner cone in it, using
press and Tool.
@I
Tool number: ST30901 000 ( )
Equivalent tool (J26010-01)

4. Place pinion front bearing inner cone in final drive housing.

5. Apply multi-purpose grease to cavity at sealing lips of oil ~11::
seal. Install front oil seal.
Tool number: ST30720000 ( )
Equivalent tool (J25405) ~IF~
"I[:;

6. Place drive pinion bearing spacer, pinion bearing adjusting

washer and drive pinion in final drive housing.

7. Insert companion flange into drive pinion by tapping the

companion flange with a soft hammer. IF/A

8. Tighten pinion nut to the specified torque.

The threaded portion of drive pinion and pinion nut should be li!liF
free from oil or grease.
Tool number: ST38060002 (J34311)

Tool

PD466

PD-33 831
 ASSEMBLY I R180A I
Final Drive Housing (Cont'd)
9. Turn drive pinion in both directions several revolutions,
and measure pinion bearing preload.
Tool number: ST3127SOOO (J25765-A}
Pinion bearing preload:
1.1 - 1.7 N·m (11 . 17 kg-em, 9.5- 14.8 in·lb}
When pinion bearing preload is outside the specifications,
replace pinion bearing adjusting washer and spacer with a dif-
ferent thickness.

SPD634

10. Select side retainer adjusting shim.

Refer to ADJUSTMENT (PD-25).
11. Press-fit side bearing outer race into side retainer.
Tool number:
@ ST30611000 (J25742-1}
@ ST30621000 (J25742-5}

Tool@
Tool@

SPD332

12. Install side oil seal.

13. Install differential case assembly.
14. Place side retainer adjusting shims (Refer to ADJUST-
MENT, PD-25.), and 0-ring on side retainer, and install
them in final drive housing.
Tool number: ST33720000 (J25817}

(
SPD660

• Align arrows stamped on side retainer and final drive hous-

ing.

15. Measure ring gear to drive pinion backlash with a dial

indicator.
Ring gear to drive pinion backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in}
• If backlash is too small, decrease thickness of right shim
and increase thickness of left shim by the same amount.
If backlash is too great, reverse the above procedure.
Never change the total amount of shims as It will change the
bearing preload.

SPD635

PD-34 832
 ASSEMBLY I R180A I
Final Drive Housing (Cont'd)
16. Check total preload with Tool.
When checking preload, turn drive pinion in both directions
several times to set bearing rollers.
Tool number: ST3127SOOO (J25765-A)
Total preload: ,!)]~
1.2- 2.3 N·m
(12 - 23 kg-em, 10- 20 in-lb)

SPD634

• If preload is too great, add the same amount of shim to

each side.
• If preload is too small, remove the same amount of shim lli::
from each side.
Never add or remove a different number of shims for each side
as it will change ring gear to drive pinion backlash.
17. Recheck ring gear to drive pinion backlash because
increase or decrease in thickness of shims will cause [Fr::;
change of ring gear to pinion backlash.

SPD561

18. Check runout of ring gear with a dial indicator.

Runout limit:
0.05 mm (0.0020 in)
• If backlash varies excessively in different places, the vari-
ance may have resulted from foreign matter caught fl\11'
between the ring gear and the differential case.
• If the backlash varies greatly when the runout of the ring
gear is within a specified range, the hypoid gear set or dif- 'JIF
ferential case should be replaced.
I 19. Check tooth contact. Refer to ADJUSTMENT (PD-30).
\ SPD636 20. Install rear cover and gasket.

21. Install extension tube and differential side shaft assembly.

SPD661

121l

PD-35 833
 tt : Adjustment is required. ~39. 49 (4. 5, 29. 36)
* Using locking agent [Locktite (stud lock) or equivalent] Filler plugD
~: N•m (kg-m, ft-lb) ~39. 59 (4. 6, 29. 43)
a: Apply recommended sealant (Nissan genuine
part: KP610-00250) or equivalent.
Rear cover
Gasket

Pinion mate shaft

~~ %~

~ 31 • 42 (3.2 • 4.3, 23 • 31)

Side bearing "TI
:II

~" lnn~ercon;e
~ 88 - 10 . .~'· o~

..::~;"" ~ ~"''" t Z J ~ , # ' i l

.-.. 98 65. 72) ~ adjusting
Drive p>mon
.
.. height
washer
« c./
o
o 0
z
~0-ring ~
1 @
0
Outer race
-1

~: - -1~-11~_j
'tl ,
"TI
c @@
'::; '2 z
/"~(fl- rt\\~lnner
,If';
gear
'
w
Q)
Differential side flange
' ·- Q )>
r
c
fl..
cone] Pinion rear bearing

~ ~Outer ~64s·d!8b~~rin~ ~d]usting <'l••-••o" , '" •. .,

I Ill :II

--~- ·- . lo::{----·-'--
·- ~ <
onvep

/1~("¥":::_:(
/ . inion beanng
. race
spacertt I
711: -/ .· bearing .._. washerr:.
rn
.,_ '"
1

o/f)J)
~ ·~ ~~-- -~
~.plug~
39-
orain 43~ ~-
-• •• -~· - '"~03
59 4 6
1 •• 29. 5 33)

Rear axle shaft bearingRear ~beanng

collaraxle .
7'f'~-0·.·--~' J
.·.

'
---
'

.
n
I.,Jf/'-., .
'f

Front oil seal ~

~

~
Companion flange Bean·ng adj"usting shim f:t "'ilJ
"'
~
Pinion nut

~
0
~186 • 294 (19. 30, 137 • 217) Extension tube retainer
~
834
 DISASSEMBLY I R200A I

Pre-inspection
Before disassembling final drive, perform the following inspec-
tion.
• Total preload
1) Turn drive pinion in both directions several times to set •!ll~
bearing rollers.
2) Check total preload with Tool.
Tool number: ST3127SOOO (J25765-A) lliiffi\
Total preload:
1.4 - 3.1 N·m (14 - 32 kg-em, 12 - 28 in-lb)
SPD664 ~iA\1l

~========~ • Ring gear to drive pinion backlash

Check backlash of ring gear with a dial indicator at several
points.
lli::
Ring gear to drive pinion backlash:
0.13- 0.18 mm (0.0051 - 0.0071 in) !:"IF i&
~~c

• Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit:
0.05 mm (0.0020 in)
• Tooth contact
Check tooth contact. Refer to ADJUSTMENT (PD-49).

• Side gear to pinion mate gear backlash

Using a feeler gauge, measure clearance between side J'ffi\
gear thrust washer and differential case.
Clearance between side gear thrust washer
and differential case: ~ffi\
0.10- 0.20 mm (0.0039- 0.0079 in)

SPD665

Final Drive Housing

1. Using three spacers [20 mm (0.79 in)], mount final drive liliF
assembly on Tool.
Tool number:
KV381 00800 ( ) ~ffi\
Equivalent tool (J34310), (J25604)

sPo•••
--------------------~~~
rmz
PD-37 835
 DISASSEMBLY I R200A I
Final Drive Housing {Cont'd)
2. Remove differential side shaft assembly.

3. Remove differential side flange.

SP0667

4. Put match marks on one side of side bearing cap with paint
or punch to ensure that it is replaced in proper position
during reassembly.
Bearing caps are line-bored during manufacture and should be
put back in their original places.

5. Remove side bearing caps.

6. Remove differential case assembly with a pry bar.

PD-38 836
 DISASSEMBLY I R200A I
Final Drive Housing (Cont'd)
Be careful to keep the side bearing outer races together with
their respective inner cones - don't mix them up.
CAUTION:
Side bearing spacer is placed on either the left or right depend-
ing upon final drive gear ratio. It should be labeled so that it @~
may be replaced correctly.

7. Loosen drive pinion nut.

Tool number: ST38060002 (J34311)
8. Remove companion flange with puller.

9. Take out drive pinion together with rear bearing inner cone,
drive pinion bearing spacer and pinion bearing adjusting
washer.
10. Remove front oil seal and pinion front bearing inner cone.

11. Remove pinion bearing outer races with a brass drift.

12. Remove pinion rear bearing inner cone and drive pinion
height adjusting washer.
Tool number: ST30031000 (J22912-01)

PD-39 837
 DISASSEMBLY I R200A I

Tool@ Differential Case

1. Remove side bearing inner cones.
To prevent damage to bearing, engage putter jaws In grooves.
Tool number:
@ ST33051 001 ( )
Equivalent tool (J22888)
@ ST33061000 (J8107·2)

SPD207A

Be careful not to confuse the right and left hand parts.

SPD022

2. Loosen ring gear bolts in a criss-cross fashion.

3. Tap ring gear off the differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

SPD024

4. Punch off pinion mate shaft lock pin from ring gear side.

Differential Side Shaft

1. Cut collar with cold chisel. Be careful not to damage differ-
ential side shaft.

PD-40 838
 DISASSEMBLY I R200A I
Differential Side Shaft (Cont'd)
2. Reinstall differential side shaft into extension tube and
secure with bolts. Remove rear axle bearing by drawing out
Without collar differential side shaft from rear axle bearing with puller.

/
/

SPD672 l(:l
::::::=================~ 3. Remove grease seal and oil seal.

SPD781

PD-41 839
 INSPECTION I R200A I

Ring Gear and Drive Pinion

Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive
pinion as a set (hypoid gear set).

Differential Case Assembly

Check mating surfaces of differential case, side gears, pinion
mate gears, pinion mate shaft and thrust washers.

SP0648

Bearing
1. Thoroughly clean bearing.
2. Check bearing for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth . rotation. If
damaged, replace outer race and inner cone as a set.

SPD715

PD-42 840
 ADJUSTMENT I R200A I

For quiet and reliable final drive operation, the following five
adjustments must be made correctly:
1. Side Bearing Preload.
2. Pinion Gear Height.
3. Pinion Bearing Preload.
4. Ring Gear to pinion Backlash. Refer to ASSEMBLY (PD-54). ~~~
5. Ring and Pinion Gear Tooth Contact Pattern.

Side Bearing Preload

Note: A selection of carrier side bearing adjusting washer is '"!:
required for successful completion of this procedure.
rEIF@
li':!:

1. Make sure all parts are clean and that the bearings are well
lubricated with light oil or Dexron type automatic transmis-
sion fluid.
2. Place the differential carrier, with side bearings and bear-
ing races installed, into the final drive housing.

3. Put the side bearing spacer in place.

CAUTION: .f'IA
Side bearing spacer is placed on either the right or left depend-
ing upon final drive gear ratio. Be sure to replace it on the cor-
~s~e. M

4. Using the J25267 side bearing shim installer, place both of

the original carrier side bearing preload shims on the car- [ijp
rier end, opposite the ring gear. "IF

PD-43 841
 ADJUSTMENT I R200A I
Side Bearing Preload (Cont'd)
5. Install the side bearing caps in their correct locations and
torque the bearing cap retaining bolts.
Specification:
88- 98 N·m (9- 10 kg-m, 65- 72 11-lb)
6. Turn the carrier several times to seat the bearings.

7. Measure the turning torque of the carrier at the ring gear

retaining bolts with a spring gauge, J8129.
Specification:
34.3 - 39.2 N (3.5 - 4 kg, 7.7 - 8.8 Ib)
of pulling force at the ring gear bolt.

8. If the carrier turning torque is not within the specification

range, increase or decrease the total thickness of the side
bearing adjusting washers until the turning torque is cor-
rect. If the turning torque is less than the specified range,
install washers of greater thickness; if the turning torque is
greater than the specification, install thinner washers. See
the SDS section for washer dimensions and part numbers.
9. Record the total amount of washer thickness required for
the correct carrier side bearing preload.

10. Remove the carrier from the final drive housing, saving the
selected preload washers for later use during the assem-
bly of the final drive unit.

Pinion Gear Height and Pinion Bearing Preload

1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion gear bearings into the pinion pre-load
shim selector Tool, J34309.

11111111111111111

SPD769

PD-44 842
 ADJUSTMENT I R200A I
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
• Front Pinion Bearing- make sure the J34309-3 front pin-
ion bearing seat is secured tightly against the J34309-2
gauge anvil. Then turn the front pinion bearing pilot,
J34309-5, to secure the bearing in its proper position. @~
• Rear Pinion Bearing - the rear pinion bearing pilot,
J34309-15, is used to center the rear pinion bearing only.
The rear pinion bearing locking seat, J34309-4, is used to 1\ii&
lock the bearing to the assembly.

3. Place the pinion preload shim selector Tool, J34309-1,

gauge screw assembly with the pinion rear bearing inner
cone installed into the final drive housing. lil:

4. Assemble the front pm1on bearing inner cone and the

J34309-2 gauge anvil together with the J34309-1 gauge
screw in the final drive housing. Make sure that the pinion
height gauge plate, J34309-16, will turn a full 360 degrees,
and tighten the two sections together by hand.

SP0199A

5. Turn the assembly several times to seat the bearings.

SPD770

6. Measure the turning torque at the end of the J34309-2

gauge anvil using torque wrench J25765A.
Turning torque specification:
1.0- 1.3 N·m (10- 13 kg-em, 8.7- 11.3 in-lb)

SPD234A

PD-45 843
 ADJUSTMENT I R200A I
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
7. Place the J34309-1 "R200A" pinion height adapter onto the
gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

SP0208A

PINION BEARING PRELOAD WASHER SELECTION

8. Place the solid pinion bearing spacer. small end first, over
the J34309-2 gauge anvil and seat the small ·end squarely
against the tip of the J34309-1 gauge screw in the tool
recessed portion.

SPD209A

SPD773

9. Select the correct thickness of pm10n bearing preload

adjusting washer using a standard gauge of 3.5 mm (0.138
in) and your J34309-101 feeler gauge. The exact measure
you get with your gauges is the thickness of the adjusting
washer required. Select the correct washer.
Drive pinion bearing preload adjusting washer:
Refer to SDS (PD-100).
10. Set your selected, correct pinion bearing preload adjusting
washer aside for use when assembling the pinion gear and
bearings into the final drive.
SPD210A

SPD774

PD-46 844
 ADJUSTMENT I R200A I
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
PINION HEIGHT ADJUSTING WASHER SELECTION
11. Now, position the side bearing discs, J25269-4, and arbor
firmly into the side bearing bores.

12. Install the side bearing caps and tighten the cap bolts.
Specification:
88- 98 N·m (9 - 10 kg-m, 65- 72 11-lb)

13. Select the correct standard pinion height adjusting washer

thickness by using a standard gauge of 3.0 mm (0.118 in)
and your J34309-101 feeler gauge. Measure the gap liil"J'
between the J34309-11 "R200A" pinion height adapter and
the arbor.

14. Write down your exact total measurement.

SPD775

15. Correct the pinion height washer size by referring to the

"pinion head number".
~[f
Note: There are two numbers painted on the pinion gear. The
first one refers to the pinion and ring gear as a matched
set and should be the same as the number on the ring ~!!\
gear. The second number Is the "pinion head height
number," and it refers to the ideal pinion height from
standard lor quietest operation. ll'IL

SPD542

PD-47 845
 ADJUSTMENT I R200A I
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
Use the following chart to determine the correct pinion height
washer.
Add or Remove from the Standard
Pinion Head Height Number Pinion Height 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)

16. Select the correct dnve p1mon he;ght washer.

Drive pinion height adjusting washer:
Refer to SDS (PD-100).

17. Remove the J34309 pinion preload shim selector tool from
the final drive housing and disassemble to retrieve the
pinion bearings.

SPD205A

PD-48 846
 ADJUSTMENT R200A

Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gear sets which are not positioned properly in relation
to one another may be noisy, or have short life, or both. With a
pattern check, the most desirable contact for low noise level
and long life can be assured.

1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered ferric oxide and oil 1.,1(:
or equivalent to 3 or 4 teeth of ring gear drive side.

SPD357

3. Hold companion flange steady by hand and rotate the ring

gear in both directions. IIJ"T

Usually the pattern will be correct If you have calculated the shims correctly and the backlash Is correct.
However, in rare cases you may have to use trial-and-error processes until you get a good tooth contact pattern. i!'lk
The tooth pattern Is the best Indication of how well a dlfterentlal has been set up.

Heel contact Face contact Toe contact Flank contact

~lk

~~
To correct, increase thickness of pinion
height adjusting washer in order to bring
To correct, reduce thickness of pinion
height adjusting washer in order to make
[8)[FJ

~v
drive pinion close to ring gear. drive pinion go away from ring gear.

___ /Vh [ID[p

~~~.

When adjustment Is completed, be sure to wipe

oft completely the ferric oxide and oil or their
equivalent.
~
~
~[,

SPD007 [[Q:J;(

PD-49 847
 ASSEMBLY R200A

\Bearing
Differential Side Shaft

t~:s;on t\u~~e=e~
1. Measure rear axle bearing end play.
Rear axle bearing end play (A - B):
0.1 mm (0.0039 in) or less
The end play can be adjusted with bearing adjusting shim.

~.-.t=~·
Refer to SDS {PD-100).

SPD206A

2. Install oil seal and grease seal.

Tool number: ST33190000 ( )
Equivalent tool (J26233)

SPD782

Tool number: (J26233)

\-------\~

Tool

•
Press 3. Install extension tube retainer, rear axle bearing and rear
Tool axle shaft bearing collar on differential side shaft.

SPD655

PD-50 848
 ASSEMBLY I R200A I

Differential Case
1. Measure clearance between side gear thrust washer and
differential case.
s Clearance between side gear thrust washer
and differential case (A - B): ·~~
0.1 0 - 0.20 mm (0.0039 - 0.0079 In)
The clearance can be adjusted with side gear thrust
washer. )II]£
Available side gear thrust washers:
Refer to SDS (PD-1 00).
2. Apply gear oil to gear tooth surfaces and thrust surfaces !;)II]
and check to see they turn properly.

rEIF@
li':!:

4. Place differential case on ring gear.

5. Apply locking agent [Locktite (stud lock) or equivalent] to .'!'&\
ring gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer. l:l&\

6. Press-fit side bearing inner cones on differential case with

Tool.
Tool number:
@ KV381 00300 (J25523)
@ ST33061 000 (J81 07-2)

PD353

PD-51 849
 ASSEMBLY I R200A I

Final Drive Housing

1. Press-fit front and rear bearing outer races with Tools.
Pinion rear
A Tool number:
@ ST30611000 (J25742-1)
@ ST30621000 (J25742-5)
© ST30613000 (J25742-3)

Pinion front
bearing outer race

SPD679

2. Select drive pm1on height adjusting washer and p1n1on

bearing adjusting washer. Refer to ADJUSTMENT (PD-44).
3. Install drive pinion height adjusting washer in drive pinion,
and press-fit pinion rear bearing inner cone in it, using
press and Tool.
Tool number: ST30901000 ( - )
Equivalent tool (J2601 0-01)

4. Place pinion front bearing inner cone in final drive housing.

~
1~
5. Apply multi-purpose grease to cavity at sealing lips of oil
seal. Install front oil seal.
Tool Tool number: KV38100500 ( - )
Equivalent tool (J25273)

PD-52 850
 ASSEMBLY I R200A I
Final Drive Housing (Cont'd)
6. Place drive pinion bearing spacer, drive pinion bearing

r A adjusting washer and drive pinion in final drive housing.

//(;(;0~,'l ~;!~~n~i~~~:er
-~
/ o Drive pinion bearing
adjusting washer
m @[:

SPD658

7. Insert companion flange into drive pinion by tapping the

companion flange with a soft hammer.

SPD6ll1 !Gl
~=============~ 8. Tighten pinion nut to the specified torque.
The threaded portion of drive pinion and pinion nut should be I¥U1r
free from oil or grease.
Tool number: ST38060002 (J34311)

PD466

9. Turn drive pomon in both directions several revolutions,

and measure pinion bearing preload. lSI!\
Tool number: ST3127SOOO (J25765-A)
Pinion bearing preload:
1.1 -1.7 N·m ifi 1~
(11 - 17 kg-em, 9.5- 14.8 in-lb)
When pinion bearing preload is outside the specifications,
replace pinion bearing adjusting washer and spacer with a dif- ~lil
ferent thickness.

10. Select side bearing adjusting washer.

Refer to ADJUSTMENT (PD-43). ~[¥'
11. Install differential case assembly with side bearing outer
races into final drive housing.

PD-53 851
 ASSEMBLY I R200A I
Final Drive Housing (Cont'd)
12. Insert left and right side bearing adjusting washers in place
between side bearings and final drive housing.

Side bearing spacer 13. Drive in side bearing spacer with Tool.

~
Tool number: KV38100600 (J25267)

SPD559

14. Align mark on bearing cap with that on final drive housing
and install bearing cap on final drive housing.

15. Apply multi-purpose grease to cavity at sealing lips of oil

seal. Install side oil seal.
Tool number: KV38100200 (J26233)

SPD560

16. Measure ring gear to drive pinion backlash with a dial

indicator.
Ring gear to drive pinion backlash:
0.13- 0.18 mm (0.0051 - 0.0071 in)
• If backlash is too small, decrease thickness of right shim
and increase thickness of left shim by the same amount.
If backlash is too great, reverse the above procedure.
Never change the total amount of shims as it will change the
bearing preload.

SPD513

PD-54 852
 ASSEMBLY I R200A I
Final Drive Housing (Cont'd)
17. Check total preload with Tool.
When checking preload, turn drive pinion in both directions
several limes to set bearing rollers.
Tool number: ST3127SOOO {J25765-A)
Total preload:
1.4- 3.1 N·m
{14 - 32 kg-em, 12- 28 in-lb)

SPD664 ~[Ml

~=============~ • If preload is too great, remove the same amount of shim

from each side.
• If preload is too small, add the same amount of shim to '"!:
each side.
Never add or remove a different number of shims for each side IEIF@
as it will change ring gear to drive pinion backlash. li':!:
18. Recheck ring gear to drive pinion backlash because
increase or decrease in thickness of shims will cause IF~
change of ring gear-to-pinion backlash.

SPD561

19. Check runout of ring gear with a dial indicator.

Runout limit:
0.05 mm {0.0020 in)
• If backlash varies excessively in different places, the vari-
ance may have resulted from foreign matter caught fll'ii'
between the ring gear and the differential case.
• If the backlash varies greatly when the runout of the ring
gear is within a specified range, the hypoid gear set or dif- :liF
ferential case should be replaced.
20. Check tooth contact. Refer to ADJUSTMENT (PD-49).
21. Install rear cover and gasket.

22. Install differential side shaft assembly.

PD-55 853
 ~"""®.
t shaft

'""-:.•. -·
~ L~
Side gear thrust washer ti

·---
Differential case
•• A
tY%f
;~o
LQV
* ~ 132 - 152 (13.5- 15.5, 98- 112)

,_ "'" ••""~"'

"tl
-- ~-
bear~ng
·-~ ~·
A ...•. .
. I
a 1l!
.•_,_
, 1\:9~ ~
I ((@
~··-59
(5.0 - 6.0, 36 - 43) ::tl
m
J>
::tl
"1'1
z
~- ~-
c
J>
g:' ~ ru
~ o& r
.~\
Hypo!'d gear set
c
,on he,ght . ::tl

Front oil seal ~

Drive .pm
adjustmg washer....-
_._ 1
S'de beanng
Side bearing cap
<
m
Drive pinion
washer ~
.
Collapsible sp acer ~

·,12-18)

~ N·m (kg-m, ft-lb)

Adjustment is required.
"* Using locking agent {Locktlte (stud lock)
or equivalent}

~
f(l
0
~
>
854
 DISASSEMBLY I H190A I

Pre-inspection
l Before disassembling final drive, perform the following inspec-
tion.
• Total preload
1) Turn drive pinion in both directions several revolutions to @~
seat bearing rollers correctly.
2) Check total preload with Tool.
Tool number: ST3127SOOO (J25765-A)
II
Tool Total preload:
II SPD149
1.2- 2.2 N·m
(12- 22 kg-em, 10 - 19 in-lb)
• Ring gear to drive pinion backlash
Check backlash of ring gear with a dial indicator at several
points. lil:
Ring gear to drive pinion backlash:
0.13- 0.18 mm (0.0051 - 0.0071 in)

SPD140

• Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit:
0.05 mm (0.0020 in)

SPD141

• Tooth contact
Check tooth contact. Refer to ADJUSTMENT (PD-67). [Cffij
Feeler
gauge
• Side gear to pinion mate gear backlash
Measure clearance between side gear thrust washer and
differential case with a feeler gauge.
l~ffii
Clearance between side gear thrust washer and
differential case:
0.10- 0.20 mm (0.0039 - 0.0079 in) !Ji<l

SPD004 ~1

Differential Carrier
1. Mount differential carrier on Tools. lil15
Tool number:
@ ST0501 SOOO ( - )
@ ST06310000 (J25602-01) f~ffij

n
®
SPD139 ~[ill:!

PD-57 855
 DISASSEMBLY I H190A I
Differential Carrier (Cont'd)
2. Put match marks on one side of side bearing cap with paint
or punch to ensure that it is replaced in proper position
during reassembly.
Bearing caps are line-bored during manufacture and should be
put back in their original places.

3. Remove side bearing caps.

Match mark
SPD009

4. Remove differential case assembly with a pry bar.

(

~
SPD010

Be careful to keep the side bearing outer races together with

&
.
their respective inner cones - do not mix them up .

i
.z:-
SPD011

5. Remove drive pinion nut with Tool.

Tool number: ST38060002 (J34311)
6. Remove companion flange with puller.

SPD213A

PD-58 856
 DISASSEMBLY I H190A I
Differential Carrier (Cont'd)
7. Remove drive pinion with soft hammer.
B. Remove oil seal.

SPD015 ~[Ml

~===;::;==========~ 9. Remove pinion bearing outer races with a brass drift.

rEIF@
li':!:

SPD563

10. Pull out rear bearing inner cone with a press and Tool.
Tool number: ST30031000 (J22912-01)

SPD018

Tool@ Differential Case

1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws In groove.
Tool number:
® ST33051 001 ( )
Equivalent tool (J22888)
@ ST33061000 (J8107-2)

SPD207A

Be careful not to confuse the left and right hand parts.

SPD022

PD-59 857
 DISASSEMBLY I H190A I
Differential Case (Cont'd)
2. Spread out lock straps and loosen ring gear bolts in a
criss-cross fashion.
3. Tap ring gear off differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

SPD024

4. Drive out pinion mate shaft lock pin, with Tool from ring
gear side.
Lock pin is calked at pin hole mouth on differential case.

SPD025

PD-60 858
 INSPECTION I H190A I

Ring Gear and Drive Pinion

Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive
pinion as a set (hypoid gear set).
@I:

Differential Case Assembly

Check mating surfaces of differential case, side gears, pinion ll\:
mate gears, pinion mate shaft, and thrust washers.

SPD239A

Bearing
1. Thoroughly clean bearing. liil1r
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If
damaged, replace outer race and inner cone as a set. 1!:1!

SPD715

PD-61 859
 ADJUSTMENT I H190A I

For quiet and reliable final drive operation, the following five
adjustments must be made correctly:
1. Side Bearing Preload.
2. Pinion Gear Height.
3. Pinion Bearing Preload. Refer to ASSEMBLY (PD-71).
4. Ring Gear-to-pinion Backlash. Refer to ASSEMBLY (PD-71).
5. Ring and Pinion Gear Tooth Contact Pattern.

Side Bearing Preload

Note:
A selection of carrier side bearing preload shims Is required for
successful completion of this procedure.

1. Make sure all parts are clean and that the bearings are well
lubricated with light oil or Dexron type automatic transmis-
sion fluid.
2. Attach side bearing puller Tools J22888 and J8107-2 to the
carrier side bearing and remove the bearings.

3. Reinstall all of the original side bearing adjusting shims on

the carrier side, away from the ring gear.

4. Reinstall the carrier side bearing using Tools J25805-01

and J8107-2. Press on the bearings.

ST33061000
IJ8107-21

PD-62 860
 ADJUSTMENT I H190A I
Side Bearing Preload (Cont'd)
5. Install carrier and bearings into the final drive housing.
Install side bearing caps. Torque the bolts and tap on the
caps with a soft hammer to seat the bearings.
Side bearing cap bolt torque:
Specification 49 - 59 N·m (5 - 6 kg-m, 36 - 43 ft-lb)

6. After turning the carrier several times to seat the bearings,

measure carrier turning force with spring gauge J8129.
Turning force specification:
34.3- 39.2 N (3.5- 4.0 kg, 7.7- 8.8 lb)
of pulling force at the ring gear bolt.

7. If necessary, correct the carrier bearing preload by adding

to or subtracting from the total amount of shim thickness.
Add shim thickness to increase turning force on the carrier.
'I
~ ... -.:__u..-
Subtract shim thickness to decrease turning force on the
carrier.
''
-----!....
'-,L

/
/ 1/ ·- SPD776

Pinion Gear Height

1. Make sure all parts are clean and that the bearings are well il'ffl
lubricated.
2. Assemble the pinion gear bearings into the pinion pre-load
shim selector tool, J34309. ~lfl

~- ~
~========~ • Front Pinion Bearing - make sure the J34309-3 front pin-
ion bearing is secured tightly against the J34309 gauge ~IS
anvil. Then turn the front pinion bearing pilot J34309-5 to
secure the bearing in its proper position.
• Rear Pinion Bearing - the rear pinion bearing pilot, ~lfl
J34309-15, is used to center the rear pinion bearing only.
The rear pinion bearing locking seat, J34309-4 is used to
lock the bearing to the assembly. ~[,

SPD197A

PD-63 861
 ADJUSTMENT I H190A I
Pinion Gear Height (Cont'd)
3. Place the pinion pre-load shim selector Tool J34309-1
gauge screw assembly with the pinion rear bearing inner
cone installed into the final drive housing.

4. Assemble the front p1n1on bearing inner cone and the

J34309-2 gauge anvil together with the J34309-1 gauge
screw in the final drive housing. Make sure that the pinion
height gauge plate, J34309-16, will turn a full 360 degrees,
and tighten the two sections together by hand.

5. Turn the assembly several times to seat the bearings.

6. Measure the turning torque at the end of the J34309-2

gauge anvil using torque wrench J25765A.
Turning torque specification:
1.0- 1.3 N·m
(10- 13 kg-em, 8.7 - 11.3 in-lb)

SPD234A

7. Place the J34309-14 pinion height adapter onto the gauge

plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

SPD208A

PD-64 862
 ADJUSTMENT I H190A I
Pinion Gear Height (Cont'd)
PINION HEIGHT ADJUSTING WASHER SELECTION
8. Now, position the side bearing discs, J25269-18, and arbor
firmly into the side bearing bores.

(.
I
SPD218A

9. Install the side bearing caps and torque the cap bolts.
Specification:
49 - 59 N·m (5 - 6 kg-m, 36 - 43 fl-lb)

rEIF@
li':!:

10. Select the correct standard pinion height adjusting washer

thickness by using J34309-101 feeler gauge. Measure the
gap between the J34309-14 pinion height adapter and the
arbor.

11. Write down your exact total measurement

SPD778

12. Correct the pinion height washer size by referring to the

"pinion head number".
Note:
There are two numbers painted on the pinion gear. The first
one refers to the pinion and ring gear as a matched set and ~til
should be the same as the number on the ring gear. The sec-
ond number is the "pinion head height number," and it refers
to the ideal pinion height from standard for quietest operation. ~IL

SP0542

PD-65 863
 ADJUSTMENT I H190A I
Pinion Gear Height (Cont'd)
Use the following chart to determine the correct pinion height
washer.
Add or Remove from the Standard
Pinion Head Height Number Pinion Height 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 O.Q1 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)

13. Select the correct pmwn hetght washer.

Drive pinion height adjusting washer:
Refer to SDS (PD-101).

14. Remove the J34309 pinion preload shim selector tool from
the final drive housing and disassemble to retrieve the
pinion bearings.

PD-66 864
 ADJUSTMENT H190A

Tooth Contact
Checking of gear tooth contact pattern is necessary to verify
correct relationship between ring gear and drive pinion.
Hypoid gear sets which are not positioned properly in relation
to one another may be noisy, or have short life, or both. With a
pattern check, the most desirable contact for low noise level
and long life can be assured.

1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered ferric oxide and oil 1,1(:
or equivalent to 3 or 4 teeth of ring gear drive side.

SPD005

3. Hold companion flange steady by hand and rotate the ring

gear in both directions. IIJ'T
\

SPD006

Usually the paHem will be correct If you have calculated the shims correctly and the backlash Is correct.
However, In rare cases you may have to use trial-and-error processes until you get a good tooth contact pattern. i!'lk
The tooth pattern Is the best Indication of how well a differential has been set up.

Heel contact Face contact Toe contact Flank contact

~lk

<!P~
To correct, increase thickness of pinion
height adjusting washer in order to bring
To correct, reduce thickness of pinion
height adjusting washer in order to make
[8)[FJ

~v
drive pinion close to ring gear.

7-;fi~ [ID[p

Correct tooth contact ~I'\

When adjustment Is completed, be sure to wipe

off completely the feme oxide and oil or their
equivalent.
~
~
~[,

SPD007 [[Q:J;(

PD-67 865
 ASSEMBLY I H190A I

Differential Case
1. Install side gears, pm10n mate gears and thrust washers
into differential case.

SPD552

rn"''"' gauge 2. Fit pinion mate shaft to differential case so that it meets
lock pin holes.
3. Adjust backlash between side gear and pinion mate gear
by selecting side gear thrust washer. Refer to SDS (PD-101).
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and dif-
ferential case):
0.10- 0.20 mm (0.0039- 0.0079 in)

4. Install pinion mate shaft lock pin with a punch.

Make sure lock pin is flush with case.

5. Apply gear oil to gear tooth surfaces and thrust surfaces

and check to see they turn properly.

6. Apply locking agent [Locktite (stud lock) or equivalent] to

II=~
contacting surfaces of ring gear and differential case, then
place differential case on ring gear .

PD-68 866
 ASSEMBLY I H190A I
Differential Case (Cont'd)
7. Apply a small amount of locking agent (described on pre-
vious page) to ring gear bolts.
8. Install new lock straps and ring gear bolts.
• Tighten bolts in a criss-cross fashion, lightly tapping boll
head with a hammer.
• Then bend up lock straps to lock the bolts in place .

9. Select side bearing adjusting shims.

Refer to ADJUSTMENT (PD-62).
10. Install the shims behind each bearing and press on side lil:
-Tool@ bearing inner cones with Tool.
Tool number:
@ ST33230000 (J25805-01)
@ ST33061000 (J8107-2)

Tool@
PD353

Differential Carrier
Tool@
1. Press fit front and rear bearing outer races with Tools.
Tool@ Tool number:
@ ST30611000 (J25742-1)
rr=rr=m~~~{I
;~J
!} @ ST30621 000 ( )
~ ST30613000 (J25742-3)

Tool@

;:
Tool@

on front
ring outer race

2. Select pinion height adjusting washer. Refer to ADJUST-

MENT (PD-63). [ills
3. Install pinion height adjusting washer in drive pinion. and
press fit rear bearing inner cone in it with press and Tool.
Tool number: ST30901000 ( )
Equivalent tool (J26010-01)

PD-69 867
 ASSEMBLY I H190A I
Differential Carrier (Cont'd)
4. Place pinion front bearing inner cone in gear carrier.

SP0581

5. Apply multi-purpose grease to cavity at sealing lips of oil

seal. Install front oil seal.
Tool number:
® ST30720000 ( )
Equivalent tool (J25405)
@ KV381 0251 0 ( )

SPD291A

Drive pinion washer 6. Install drive pinion washer, collapsible spacer and drive
Collapsible spacer pinion in gear carrier.

7. Install companion flange and hold it firmly.

Insert pinion into companion flange by tapping its head with
a soft hammer.

8. Temporarily tighten pinion nut until there is no axial play.

Toot
The threaded portion of drive pinion and pinion nul should be
free from oil or grease.
Tool number: ST38060002 (J34311)

PD-70 868
 ASSEMBLY I H190A I
Differential Carrier (Cont'd)
9. Tighten pinion nut by degrees to the specified preload
while checking the preload with Tools.
When checking preload, turn drive pinion in both directions
several times to seat bearing rollers correctly.
Pinion bearing preload:
1.1- 1.6 N·m (11 -16 kg-em, 9.5- 13.9 in-lb)
Tool number: ST3127SOOO (J25765-A)
CAUTION:
The preload is achieved by using the permanent set of collaps-
ible spacer. So here, if an overpreload results from excessive
SP0149 turning of the pinion nut, the spacer should be replaced by new
one.
10. Install differential case assembly with side bearing outer
races into gear carrier.

SPD011

11. Align mark on bearing cap with that on gear carrier and
install bearing cap on gear carrier.

SPD043

12. Measure ring gear to drive pinion backlash with a dial

indicator.
Ring gear to drive pinion backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in)
• If backlash is too small, decrease thickness of left shim and
increase thickness of right shim by the same amount.
• If backlash is too great, reverse the above procedure.
Never change the total amount of shims as it will change the liji!J
bearing preload.

13. Check total preload with Tool.

When checking preload, turn drive pinion in both directions Ill"
several times to set bearing rollers.
Tool number: ST3127SOOO (J25765-A)
Total preload: r~~
1.2 - 2.2 N·m (12 - 22 kg-em, 10- 19 in-lb)

SPD149

PD-71 869
 ASSEMBLY I H190A I
Differential Carrier (Cont'd)
• If preload is too great, remove the same amount of shims
from each side.
• If preload is too small, add the same amount of shims to
each side.
Never add or remove a different number of shims lor each side
as it will change ring gear-to-drive pinion backlash.
14. Recheck ring gear-to-drive pinion backlash because an
increase or decrease in thickness of shims will cause
change of ring gear-to-pinion backlash.

SPD031

15. Check runout of ring gear with a dial indicator.

Runout limit: 0.05 mm (0.0020 in)
• If backlash varies excessively in different places, the vari-
ance may have resulted from foreign matter caught
between the ring gear and the differential case.
• If the backlash varies greatly when the runout of the ring
gear is within a specified range, the hypoid gear set or dif-
ferential case should be replaced.
16. Check tooth contact.
Refer to ADJUSTMENT (PD-67).
SPD141

PD-72 870
 N
'
'!1.
:::>
t shaft
a·
:::>

~""'~1
~
r Pinion ma e\hrust block

.A:) ~Pimon mate::~~

~(Q
thrust washer
rlmon

\ "" '
<&'. ~@ @~ r~132-152(13.5-1.,
Differential case

~&~ ll!J ~
"""
~f@'
\
j ·~ ·-· " • ' "'
-··-
1
Side gear thrust washer<c adjuster«

Side gear ~~'!?Jil r

Lockp1n~ J ,
~~'//t6Jj
~ o@,
~ 93- 10130 5 69 • 76)
(9.5- ., :D
m

'tl
c
Dnve ptmon

~er ~
g
rear beanng
outer cone Drive
I
I
p1n1on
*

..
I
Ring gear
I.
'
\)
co~
fb~
~ "'* ~~~
J

Jnne; ~a~ir
~ ~
I .
'fM
l>
:D
:!!
z
~
tN .

.:... l>
w
race
\\1
'd gear set
Hypo! Side beanng
r
c
:D

Front oil seal ~

. .
Drive pmlon height adjusting
Side bearing cap
<
m
washer-tr
I I

~~ ~
1.. Pinion bearing spacer

I
. ·on bean·ng adjusting sh'lm "
Drive pim

<0/
\w ~100-2M
\_Apply differential oil to thread.
t:C.l 54 - 64 (5.5 - 6.5, 40 - 47)
~-~. 1 ~-210)

~
~ ' N•m (kg-m, ft-lb)
00
~
* : Adjustment is required.
2
~
>
871

m ~ rm ~ 9 ~ ~ IBl ~ ~ ~
~~ ~
~
ljjjjJ W! 29 0'\Jj

~
~ ~ =Jill 9 :om ~--, ~ "iCl 9 9 F 0'\Jj
~ ~ ~

"""
 ...'
"':rs·
~ ~p ~~erential
"
r Pinion mate t hrust washer
"
!
case

~~~
~
Plmon rna t e gear
"'
CD

v~@
shaft

@J
~
;;;
A2:.. ~
rA S;de gear
Side gear thrust washer"

~ Rmg gear

~® ~ Iff} ~
t1n ( } )0 0
0

iI Side bearing r Side bearing

">m
(@ 0 /
~ adjuster~
Gasket
Drive pini.on ~ 0
rear beanng
0 Inner Outer
I
Side bearing cap

"z
Differential carrie~ cqne race

~@!*~""'
'tl Drive pil !!

L
, @;}'\n\1
c
®~ \ >
~
'
...... Hypold gear set
r
""
F'~\ A• ,.,, : ••\
c
"<m
I
i'i")J '-Drive pinion height
adjusting washer-& Differential case couple bolt
Companion flange tDJ 64 - 74 (6.5 - 7.5, 47 - 64)
Pinion bearing spacer Ring gear bolt

I
tDJ 132 - 152 (13.5 - 15.5, 98 - 112)

Drive pinion bearing adjusting shim -t.r

~ Front oil seal ~

~~(g)
\tDJ8-11 )
(0.8 - 1.1, 5.8 - 8.0)
\
tDJ 196 - 284 /"
(20 - 29, 145 - 210) @~
tDJ : N-m (kg-m. tt-lb)
1:! , Adjustment is required.
w \Apply differential oil to thread.
*: Applied to models equipped
~ with rear drum brake
0 tDJ 64 - 64 (5.5 - 6.5, 40 - 47)
~ 00
872
 DISASSEMBLY I H233B I

Pre-inspection
Before disassembling final drive, perform the following inspec-
tion.
• Total preload 1\li[:
1) Turn drive pinion in both directions several times to seat
bearing rollers correctly.
2) Check total preload with Tool.
Total preload:
1.7- 2.5 N·m
(17- 25 kg-em, 15- 22 in-lb)
Tool number: ST3127SOOO (J25765-A)
• Ring gear to drive pinion backlash
Check backlash of ring gear with a dial indicator at several ll\:
points.
Ring gear-to-drive pinion backlash:
0.15- 0.20 mm (0.0059- 0.0079 in)

• Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit:
0.08 mm (0.0031 in)

SPD247

• Tooth contact
Check tooth contact, referring to ADJUSTMENT (PD-90).
lSI!\
Feeler
gauge
• Side gear to pinion mate gear backlash
Measure clearance between side gear thrust washer and
differential case with a feeler gauge. [p(/.~
Clearance between side gear thrust washer and
differential case:
0.10- 0.20 mm (0.0039- 0.0079 in) ~[ffi

illi
Differential Carrier
1. Mount final drive assembly on Tool. [81~
Tool number: ST06340000 ( )
Equivalent tool (J25602-3), (J34310)
frlffil

l':l

SPD6B3 ~~}:1

PD-75 873
 DISASSEMBLY I H233B I
Differential Carrier (Cont'd)
2. Put match marks on one side of side bearing cap with paint
or punch to ensure that it is replaced in proper position
during reassembly.
Bearing caps are line-bored during manufacture and should be
put back in their original places.

3. Remove side lock fingers and side bearing caps.

Match mark

4. Remove side bearing adjuster with Tool.

Tool number: ST32580000 (J34312)

5. Remove differential case assembly with a pry bar.

Be careful to keep the side bearing outer races together with

their respective inner cones - do not mix them up.

SPD011

PD-76 874
 DISASSEMBL V I H233B I
Differential Carrier (Cont'd)
Tool
6. Remove drive pinion nut with Tool.
Tool number: KV38104700 {J34311)
7. Remove companion flange with puller.
8. Remove ABS sensor. (Models with ABS)

~M ~

~::====:;;;.==~~~====~ 9. Take out drive prmon together with prnron rear bearing
inner cone, drive pinion bearing spacer and pinion bearing
adjusting shim. lil:

Brass drift

II
10. Remove front oil seal and pinion front bearing inner cone.
11. Remove pinion bearing outer races with a brass drift.

SPD563

12. Remove pinion rear bearing inner cone and drive pinion
adjusting washer.
Tool number: ST30031000 {J22912-01)

SPD018

Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove.
Tool number:
@ ST33051 001 { )
Equivalent tool {J22888)
@ ST33061000 {J8107-2)

SPD207A

PD-77 875
 DISASSEMBLY I H233B I
Differential Case (Cont'd)
Be careful not to confuse the left and right hand parts.

SPD022

2. Spread out lock straps and loosen ring gear bolts in a

criss-cross fashion.

SPD689

3. Tap ring gear off differential case with a soft hammer.

Tap evenly all around to keep ring gear from binding.

SPD024

4. Drive out pinion mate shaft lock pin, with punch from ring
gear side (2-pinion type differential case).
lock pin is calked at pin hole mouth on differential case.

5. Separate differential case LH and RH (4-pinion type differ-

ential case).
Put match marks on both differential case LH and RH sides
prior to separating them.

PD-78 876
 INSPECTION I H233B I

Ring Gear and Drive Pinion

Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive
pinion as a set (hypoid gear set).
@I

2-pinion type Differential Case Assembly

Check mating surfaces of differential case, side gears, pinion ~:r::
mate gears, pinion mate shaft, and thrust washers.

4-pinion type

1?/Jc

[gji§J

~lil

SPD717 ~r

Bearing
1. Thoroughly clean bearing. ~IF
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If
damaged, replace outer race and inner cone as a set. l~ffi\

n
SPD715
r~JZ

PD-79 877
 LIMITED SLIP DIFFERENTIAL I H233B I

Differential case
No. of discs and plates (One side)
couple bolt
~el H2338
lOJ54 • 64 (5.5 • 6.5, 40 • 47)\

Friction disc
Lock strap~~\
5
Friction plate 6 ~~
Spring disc I '' ~
Spring plate I
r Pinion mate shaft . . ... : ~'
I . "'. ~~. ~\(J ~·I
'I1 /
Friction plate* @)

~
Friction dose*
@~
1
®Jl vt1\)~ ~
I II ;
Friction plate l / / Y§! · L Differential
guide ~~ case"B

Olfferentla~~ase . A'' ~ "" ~)\ ~. ~ r@ '-Thrust block

1
" " .··. ~1)~1~ \ @) \ ~ Ponton mate thrust washer

o ~ ~ ~\d) IP \ {_ Ponton mate gear ,.,

1) \ .-.. N•m (kg-m, ft-lb)

0
! \ S1de gear
* : For number of discs of plates,
\_ Spring plate* refer to table.
SPD252A

CAUTION:
Do not run engine when one wheel (rear) is off the ground.

Preparation for Disassembly

CHECKING DIFFERENTIAL TORQUE
Measure differential torque with Tool.
If it is not within the specifications, inspect components of lim-
ited slip differential.
Tool®- / Differential torque:
353- 392 N·m
(36 - 40 kg-m, 260 - 289 11-lb)
Tool number:
@ KV381 0521 0 ( )
@ KV381 05220 ( )

Disassembly
1. Remove side bearing inner cone with Tool.
2. Remove ring gear by spreading out lock straps.
3. Loosen ring gear bolts in a criss-cross fashion.
4. Tap ring gear off gear case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

PD-80 878
LIMITED SLIP DIFFERENTIAL I H233B I
Disassembly {Cont'd)
5. Remove differential case by spreading out lock straps.
6. Remove couple bolts on differential cases A and B with a
press.
Tool number: ST33081000 (
7. Separate differential case A and B.
Draw out component parts (discs and plates, etc.).
Put marks on gears and pressure rings so that they can be
reinstalled in their original positions from which they were
removed.

Inspection
CONTACT SURFACES
1. Clean the disassembled parts in suitable solvent and blow
dry with compressed air. !ElF@
2. If following surfaces are found with burrs or scratches, li':!:
smooth with oil stone.
CD Differential case A IF~
® Differential case B
@ Side gear
@ Pinion mate gear t:;[L
® Pinion mate shaft
® Thrust block
(!) Friction plate guide 1~1

SPD291

DISC AND PLATE

1. Clean the discs and plates in suitable solvent and blow dry .f'IA
with compressed air.
2. Inspect discs and plates for wear, nicks and burrs.

3. To test if friction disc or plate is not distorted, place it on a

surface plate and rotate it by hand with indicating finger of [ijfF
dial gauge resting against disc or plate surface.
Allowable warpage:
0.05 - 0.15 mm (0.0020 - 0.0059 in)
If it exceeds limits, replace with a new plate to eliminate
possibility of clutch slippage or sticking.

PD-81 879
 LIMITED SLIP DIFFERENTIAL H233B

Inspection (Cont'd)
4. Measure frictional surfaces and projected portions of fric-
tion disc, friction plate, spring plate, and determine each
part's differences to see if the specified wear limit has been
exceeded.
5. Measure frictional surfaces and projected portions of fric-
tion disc, friction plate; spring plate and spring disc (H233B
only).
If any part has worn beyond the wear limit, replace it with a new
B
one that is the same thickness as the projected portion.
A Wear limit:
0.1 mm (0.004 in) or less

?f\
.~. ··0·· •
•
• : Measuring points
A : Projected portion
B : Frictional surface
A- B =Wear limit mm (in)

SPD403

Adjustment
FRICTION DISC AND FRICTION PLATE END PLAY
End play of friction disc and friction plate can be calculated by
using following equation and should be adjusted within follow-
ing range.
Adjustment can be made by selecting friction disc having two
different thicknesses.
End play E:
0.05- 0.15 mm {0.0020- 0.0059 in)
E = A- {B + C)
A: Length of differential case contact surface to differ-
ential case inner bottom.
B: Total thickness of friction discs, friction plates,
spring disc and spring plate in differential case on
one side.
C: Length of differential case contact surface to back
side of side gear.

Differential case B Dip caliper Differential 1. Measure values of "A".

case A Standard length A:
49.50 - 49.55 mm (1.9488 - 1.9508 in)

SPD417

PD-82 880
 LIMITED SLIP DIFFERENTIAL I H233B I
Adjustment (Cont'd)
2. Measure thickness of each disc and plate.
Total thickness "B":
19.24- 20.26 mm (0.7575- 0.7976 in)

SPD420

3. Measure values of "C".

(1) Attach a dial indicator to the base plate.
(2) Place differential case B on the base plate, and install a lil:
Suitable block
master gauge on case B.
Then adjust the dial indicator scale to zero with its tip on the
master gauge.

SPD418

(3) Install pinion mate gears, side gears and pinion mate shaft
in differential case B.
(4) Set dial indicator's tip on the side gear, and read the indi-
Suitable block cation.
!master gauge 30mm Example:
(1.18inl1
E ~ A-D ~ A- (B + C) ~ 0.05 to 0.15 mm
A~ 49.52 mm
B ~ 19.45 mm
C ~ 29.7 mm
D~B+C E ~A-D
SPD419 B ... 19.45 A ... 49.52
+C ... 29.7 -D ... 49.15

49.15 0.37

From the above equation, end play of 0.37 mm exceeds the

specified range of 0.05 to 0.15 mm. IRtl!
Select suitable discs and plates to adjust correctly.

Assembly
Friction disc Prior to assembling discs and plates, properly lubricate them Ill"
by dipping them in limited slip differential oil.
1. Alternately position specified number of friction plates and
Friction plate friction discs on rear of side gear. f~tl!
Always position a friction plate first on rear of side gear.

SPD421

PD-83 881
LIMITED SLIP DIFFERENTIAL I H233B I
Assembly (Cont'd)
2. Install spring disc.
Align the twelve angular holes in spring disc with the hexago-
nal area of the side gear.

SPD422

3. Install spring plate.

SPD423

4. Install friction plate guides.

Correctly align the raised portions of friction plates, and apply
grease to inner surfaces of friction plate guides to prevent them
from falling.

5. Install differential case B over side gear, discs, plates and

friction plate guide assembly.
• Install differential case B while supporting friction plate
guides with your middle finger inserted through oil hole in
differential case.
• Be careful not to detach spring disc from the hexagonal
part of the side gear.

6. Install pinion mate gears and pinion shaft to differential

case B.

SPD426

PD-84 882
LIMITED SLIP DIFFERENTIAL I H233B I
Assembly (Cont'd)
7. Install thrust block.

8. Install side gear to pinion mate gears.

9. Install each disc and plate.
Use same procedures as outlined in steps 1. through 4. above.
l\\:

10. Install differential case A.

Position differential cases A and B by correctly aligning marks iill1!'
stamped on cases.

11. Tighten differential case bolts.

12. Place ring gear on differential case and install new lock IC!l\
straps and bolts.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer. IR!l\
Then bend up lock straps to lock the bolts in place.
13. Install side bearing inner cone.
14. Check differential torque. liJI<l

PD-85 883
 ADJUSTMENT I H233B I

For quiet and reliable final drive operation, the following five
adjustments must be made correctly:
1. Side Bearing Preload.
2. Pinion Gear Height.
3. Side Bearing Preload.
4. Ring Gear to pinion Backlash. Refer to ASSEMBLY (PD-95).
5. Ring and Pinion Gear Tooth Contact Pattern.

Pinion Bearing Preload and Pinion Gear Height

1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion gear bearings into the pinion pre-load
shim selector tool, J34309.

SPD196A

• Rear Pinion Bearing - the rear pm1on bearing pilot,

J34309-8, is used to center the rear pinion bearing only. The
rear pinion bearing locking seat, J34309-4, is used to lock
the bearing to the assembly.
• Front Pinion Bearing - make sure he J34309-3, front pin-
ion bearing seat is secured tightly against the J34309-2
gauge anvil. Then turn the front pinion bearing pilot,
J34309-5, to secure the bearing in its proper position.

3. Place the pinion preload shim selector tool gauge screw

assembly, J34309-1, with the pinion rear bearing inner cone
installed, into the final drive housing.

4. Install the J34309-2 gauge anvil with the front pinion bear-
ing into the final drive housing and assemble it to the
J34309-1 gauge screw. Make sure that the J34309-16 gauge
plate will turn a full 360 degrees, and tighten the two sec-
\ tions by hand to set bearing pre-load.
/)~ 5. Turn the assembly several times to seat the bearings.

;--
\"-. SPD217A

PD-86 884
 ADJUSTMENT I H233B I
Pinion Bearing Preload and Pinion Gear Height
(Cont'd)
6. Measure the turning torque at the end of the J34309-2
gauge anvil using torque wrench J25765A.
Turning torque specitication:
0.4 - 0.9 N·m (4 - 9 kg-em, 3.5- 7.8 in-lb) @~

SPD234A

7. Place the J34309-12 "H233B" pinion height adapter onto the

gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

SPD208A

PINION BEARING PRELOAD WASHER SELECTION

8. Place the solid pinion bearing adjusting spacer squarely iill1!'
into the recessed portion of the J34309-2 gauge anvil. Rest
its end on the J34309-1 gauge screw.

9. Select the correct thickness of pm1on bearing preload

adjusting washer using your J34309-101 feeler gauge. The IC!l\
exact measurement you get with your feeler gauge is the
thickness of the adjusting shim required. Select the correct
shim.
Drive pinion bearing preload adjusting shim:
Refer to SDS (PD-103).
10. Set correct pinion bearing preload adjusting shim aside for liji<J
use when assembling the pinion and bearings into the final
drive housing.

PINION HEIGHT ADJUSTING WASHER SELECTION

11. Position the J25269-18 side bearing discs and the arbor into Ill"
the side bearing bores.

SPD286A

PD-87 885
 ADJUSTMENT I H233B I
Pinion Bearing Preload and Pinion Gear Height
(Cont'd)
12. Install the bearing caps and torque the bolts.
Specification:
93- 103 N·m (9.5- 10.5 kg-m, 69- 76 11-lb)

13. Select the correct standard pinion height adjusting washer

thickness using a standard gauge of 2.5, 3.0, or 3.5 mm
(0.098, 0.118, or 0.138 in) and your J34309-101 feeler gauge.
Measure the distance between the J34309-12 "H233B" pin-
ion height adapter and the arbor.

14. Write down your exact total measurement.

SPD779

15. Correct the pinion height washer size by referring to the

"pinion head height number".
Note: There are two numbers painted on the pinion gear. The
first one refers to the pinion and ring gear as a matched
set and should be the same as the number on the ring
gear. The second number is the "pinion head height
number," and it refers to the ideal pinion height from
standard for the quietest operation. Use the following
chart to determine the correct pinion height washer.

SPD542

PD-88 886
 ADJUSTMENT H233B

Pinion Bearing Preload and Pinion Gear Height

(Cont'd)

Add or Remove from the Selected

Pinion Head Height Number Standard Pinion Height 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 O.D3 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)
rEIF@
+3 Subtract 0.03 mm {0.0012 in)
li':!:
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm {0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)

16. Select the correct pm1on height washer.

Drive pinion height adjusting washer:
Refer to SDS (PD-102).

17. Remove the J34309 pinion preload shim selector tool from
the final drive housing and disassemble to retrieve the :f'IA
pinion bearings.

PD-89 887
 ADJUSTMENT H233B

Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gear sets which are not positioned properly in relation
to one another may be noisy, or have short life or both. With a
pattern check, the most desirable contact for low noise level
and long life can be assured.

1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered ferric oxide and oil
or equivalent to 3 or 4 teeth of ring gear drive side.

SPD005

3. Hold companion flange steady by hand and rotate the ring

gear in both directions.

Usually the pattern will be correct If you have calculated the shims correctly and the backlash Is correct.
However, In rare cases you may have to use trial·and.error processes until you get a good tooth contact pattern.
The tooth pattern Is the best Indication of how well a differential has been set up.

Heel contact Face contact Toe contact Flank contact

~~
To correct, increase thickness of pinion
height adjusting washer In order to bring
To correct, reduce thickness of pinion
height adjusting washer in order to make
drive pinion close to ring gear. drive pinion go away from ring gear.

,___,/~6
When adjustment Is completed, be sure to wtpe
off completely the ferric oldde and oil or their
equivalent. ~
~ SPD007

PD-90 888
 ASSEMBLY I H233B I

Differential Case - 2-pinion type -

1. Install side gears. pinion mate gears and thrust washers
into differential case.

2. Fit pinion mate shaft to differential case so that it meets

lock pin holes.
3. Adjust backlash between side gear and pinion mate gear '"!:
by selecting side gear thrust washer.
Refer to SDS (PD-102).
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and
differential case):
0.10- 0.20 mm (0.0039- 0.0079 in)

4. Install pinion mate shaft lock pin with a punch.

Make sure lock pin is flush with case.

5. Apply gear oil to gear tooth surfaces and thrust surfaces

and check to see they turn properly.
oil 6. Install differential case assembly on ring gear.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer. l:lffil

SPD322

7. Press-fit side bearing inner cones on differential case with

Tool.
Tool@ Tool number:
@ ST33190000 ( )
Equivalent tool (J25523)
@ ST33081 000 ( )

Tool@
PD244

PD-91 889
 ASSEMBLY I H233B I

Differential Case - 4-pinion type -

1. Measure clearance between side gear thrust washer and
differential case.
s Clearance between side gear thrust washer
and differential case (A - B):
0.10- 0.20 mm (0.0039- 0.0079 in)
The clearance can be adjusted with side gear thrust
washer. Refer to SDS (PD-102).
2. Apply gear oil to gear tooth surfaces and thrust surfaces
and check to see they turn properly.

3. Install differential case LH and RH.

4. Install differential case on ring gear.

5. Place differential case on ring gear.

6. Apply locking agent [Locktite (stud lock) or equivalent] to
ring gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.

SPD746

7. Press-fit side bearing inner cones on differential case with

Tool.
Tool number:
Tool@
@ ST33190000 ( )
Equivalent tool (J25523)
® ST33081 000 ( )

Tool@
PD353

PD-92 890
 ASSEMBLY I H233B I

Differential Carrier
Tool@
1. Press-fit front and rear bearing outer races with Tools.
_Tool@ Tool number:
® ST30611000 (J25742-1)
rnr=mt:~~" ~
~~T
@ ST30621000 (J25742-5)
© ST30613000 (J25742-3)

Pinion rear
bearing outer race

Tool@

;:
Tool@

on front
ring outer race

2. Select drive pm1on adjusting washer. Refer to ADJUST-

MENT {PD-86).
3. Install drive pinion adjusting washer in drive pinion, and
IIJ'T
press-fit pinion rear bearing inner cone in it, with press and
Tool.
Tool number: ST30901000 ( )
Equivalent tool (J2601 0-01)

4. Place pinion front bearing inner cone in gear carrier.

SPD581

5. Apply multi-purpose grease to cavity at sealing lips of oil

seal. Install front oil seal.
Tool number:
@ ST30720000 ( )
Equivalent tool (J25405)
@ KV381 02510 ( )

PD-93 891
 ASSEMBLY I H233B I
Differential Carrier (Cont'd)
6. Install drive pinion bearing spacer, pinion bearing adjust-
Drive pinion bearing spacer
ing shim and drive pinion in gear carrier.

7. Insert companion flange into drive pinion by tapping the

companion flange with a soft hammer.

8. Tighten pinion nut to the specified torque.

The threaded portion of drive pinion and pinion nut should be
free from oil or grease.
Tool number: KV38104700 (J34311)

9. Turn drive pinion in both directions several times, and mea-

sure pinion bearing preload.
Tool number: ST3127SOOO (J25765-A)
Pinion bearing preload (Without front oil seal):
1.2- 1.5 N·m (12- 15 kg-em, 10- 13 in-lb)

10. Install differential case assembly with side bearing outer

races into gear carrier.
11. Position side bearing adjusters on gear carrier with
threads properly engaged; screw in adjusters lightly at this
stage of assembly.
Tool number: ST32580000 (J34312)

PD-94 892
 ASSEMBLY I H233B I
Differential Carrier (Cont'd)
12. Align mark on bearing cap with that on gear carrier and
install bearing cap on gear carrier.
• Do not tighten at this point to allow further tightening of side
bearing adjusters.

13. Tighten both right and left side bearing adjusters alter-
nately and measure ring gear backlash and total preload at
the same time. Adjust right and left side bearing adjusters '"!:
by tightening them alternately so that proper ring gear
backlash and total preload can be obtained. !ElF@
Ring gear-to-drive pinion backlash: li':!:
0.15- 0.20 mm (0.0059 - 0.0079 in)

• When checking preload, turn drive pinion in both directions

several times to set bearing rollers. 1~1
Tool number: ST31275000 (J25765-A)
Total preload:
1.7- 2.5 N·m (17- 25 kg-em, 15- 22 in-lb) fll'ii'

14. Tighten side bearing cap bolts.

15. Install side lock finger in place to prevent rotation during :r:&
operation.

16. Check runout of ring gear with a dial indicator.

Runout limit: 0.08 mm (0.0031 in)
~IF
• If backlash varies excessively in different places, the vari-
ance may have resulted from foreign matter caught
between the ring gear and the differential case.
• If the backlash varies greatly when the runout of the ring
gear is within a specified range, the hypoid gear set or dif-
ferential case should be replaced.
17. Check tooth contact. Refer to ADJUSTMENT (PD-90).

SPD247

PD-95 893
 SERVICE DATA AND SPECIFICATIONS (SDS)

Propeller Shaft
GENERAL SPECIFICATIONS
2WD models
Engine KA24E VG30E

Wheelbase Standard Long Standard Long

Transmission MiT AiT MiT AIT MiT AiT MiT AiT

Propeller shaft model 3S71A 3S80B

Number of joints 3

Coupling method with

Sleeve type
transmission

Type of journal bearings Shell type {non-disassembly type) Solid type (disassembly type)

Distance between yokes

71 (2.80) 80 (3.15)
mm (in)

Shaft length mm (in)

(Spider to spider)

665 565 665 565 690 590 690 590

1st
(26.18) (22.24) (26.18) (22.24) (27.17) (23.23) (27.17) (23.23)

2nd 680 (26.77) 980 (38.58) 650 (25.59) 960 (37.80)

Shaft outer diameter

mm (in)

1st 75 (2.95)

2nd 65 (2.56)

4WD models
Location Front Rear

Wheelbase - Standard Long

Engine - KA24E VG30E KA24E VG30E

Transmission MiT AiT -

Propeller shaft model 2F71H 28808 3S80B

Number of joints 2 3

Coupling method with transmis-

Flange type Sleeve type
sian

Type of journal bearings Solid type (disassembly type)

Distance between yokes mm (in) 71 (2.80) 80 (3.15)

Shaft length mm (in)

(Spider to spider)

542 540 940 430

1st
(21.34) (21.26) (37.01) (16.93)

810
2nd -
(31.89)

Shaft outer diameter mm (in)

65 50.8 65 75 65 75
1st
(2.56) (2.000) (2.56) (2.95) (2.56) (2.95)

65 75
2nd -
(2.56) (2.95)

PD-96 894
 SERVICE DATA AND SPECIFICATIONS (SDS)
Propeller Shaft (Cont'd)
SERVICE DATA
Unit: mm (in)

Propeller shaft runout limit 0.6 (0.024)

Journal axial play 0.02 (0.0008) or less

Snap ring (808)

Unit: mm (in)

Thickness Color Part number

1 99 (0.0783) White 37146-C9400

2 02 (0.0795) Yellow 37147-C9400

2.05 (0.0807) Red 37148-C9400

2.08 (0.0819) Green 37149-C9400

2 11 (0.0831) Blue 37150-C9400

2.14 (0.0843) Light brown 37151-C9400

2 17 (0.0854) Black 37152-C9400

2.20 (0.0866) No paint 37153-C9400

Snap ring (71 H)

Unit mm (in)

Thickness Color Part number

1.99 (0.0783) White 37146-01GOO

2.02 (0.0795) Yellow 37147-01GOO

2.05 (0.0807) Red 37148-01GOO

2.08 (0.0819) Green 37149-01800

2.11 (0.0831) Blue 37150-01GOO

2.14 (0.0843) Light brown 37151-01GOO

2.17 (0.0854) Pink 37152-01800

2.20 (0.0866) No paint 37153-01800

PD-97 895
 SERVICE DATA AND SPECIFICATIONS (SDS)

Final Drive
GENERAL SPECIFICATIONS
2WD models
Engine KA24E VG30E

Vehicle type - Truck Wagon

Transmission MIT AIT MIT AIT MIT

I AfT -

Body type - Except Heavy duty Heavy duty -

Final drive model

Rear H190A H233B

Number of pinions 2 4

4.375
Gear ratio 3.545 3.700 3.900 4.625 4.375
4.625*1

Number of teeth 35/8

39/11 37/10 39/10 37/8 35/8
(Ring gear/drive pinion) 37/8*1

Oil capacity (Approx.)

1.5 (3-118, 2-5/8) 2.8 (5-7/8, 4-7/8)
1 (US pt, Imp pt)
..
1. Opttonal ttre (P235/75) equtpped models

4WD models
Engine KA24E VG30E

Vehicle type - - I Truck Wagon

Transmission - MIT AIT

Except
Vehicle grade - - SE
I SE
Final drive
model

Front R180A R200A

Rear H2338

4.375
Gear ratio 4.375 4.625
4.625*1

Number of pin-
ions

Front 4
Rear 4
Number of teeth
35/8
(Ring gear/drive 35/8 37/8
37/8.1
pinion)

Oil capacity
(Approx.)
( (US pt, Imp pt)

1.3
Front (2-314, 1.5 (3-1/8, 2-5/8)
2-1/4)

Rear 2.8 (5-718, 4-7/8)

.1. Opt1onal t1re (31 x l0.5R15LT and P235/75) equ1pped models.

PD-98 896
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont'd)
INSPECTION AND ADJUSTMENT (R180A) Drive pinion height adjustment
Available pinion height adjusting washers
Ring gear runout
Thickness mm (in) Part number
Ring gear runout limit mm (in) 0.05 (0.0020)
3.09 (0.1217) 38154-84017
3.12 (0.1228) 38154-64018
Axle bearing adjustment 3.15 (0.1240) 38154-84019
3.18 (0.1252) 38154-84020
Axle bearing end play mm (in) 0-0.1 (0- 0.004) 3.21 (0.1264) 38154-E4600
Available axle bearing adjusting shims 3.24 (0.1276) 38154-E4601
3.27 (0.1287) 38154-E4602
Thickness mm {in) Part number 3.30 (0.1299) 38154-E4603
0.10 (0.0039) 38233-01G11 3.33 (0.1311) 38154-E4604
0.20 (0 0079) 38233-01812 3.36 (0.1323) 38154-E4605
0.30 (0.0118) 38233-01 G 13 3.39 (0.1335) 38154-E4606
0.40 (0.0157) 38233-01G14 3.42 (0.1346) 38154-E4607
0.50 (0.0197) 38233-01810 3.45 (0.1358) 38154-E4608
3.48 (0.1370) 38154-E4609
3.51 (0.1382) 38154-E4610
Side gear adjustment 3.54 (0.1394) 38154-E4611
3.57 (0.1406) 38154-E4612
Side gear backlash 3.60 (0.1417) 38154-E4613
0.10-0.20
(Clearance between side gear and 3.63 (0.1429) 38154-E4614
(0.0039 - 0.0079)
differential case) mm (in) 3.66 (0.1441) 38154-E4615
Available side gear thrust washers

Thickness mm {in) Part number Drive pinion preload adjustment

0.75- 0.78 (0.0295- 0.0307) 38424-W2010 Drive pinion preload
0.78 - 0.81 (0.0307 - 0.0319) 38424-W2011 N·m (kg-em, in-!b)
0.81 - 0.84 (0.0319- 0.0331) 38424-W2012
0.84 - 0.87 {0.0331 - 0.0343) 38424-W2013 1.1 - 1.7
With front oil seal
0.87 - 0.90 (0.0343 - 0.0354) 38424-W2014 {11- 17, 9.5- 14.8)
0.90 - 0.93 (0.0354 - 0.0366) 38424-W2015 Available drive pinion bearing preload adjusting washers
0.93- 0.96 (0.0366- 0.0378) 38424-W2016
0.96 - 0.99 (0.0378 - 0.0390) 38424-W2017 Thickness mm (in) Part number

6.59 (0.2594) 38127-0iGOO

6.57 {0.2587) 38127-01G01
Side bearing adjustment 6.55 (0.2579) 38127-01G02
Differential carrier assembly turn- 6.53 (0.2571) 38127-01G03
34.3- 39.2 6.51 (0.2563) 38127-01G04
ing resistance
(3.5- 4.0, 7.7- 8.8) 6.49 (0.2555) 38127-01G05
N (kg, lb)
6 47 (0.2547) 38127-01G06
Available side retainer shims 6.45 (0.2539) 38127-01G07
Thickness mm {in) Part number 6.43 {0.2531) 38127-01G08
6.41 {0.2524) 38127-01G09
0.20 (00079) 38453-01GOO 6 39 (0.2516) 38127-01G10
0.25 (0.0098) 38453-01 G01 6.37 (0.2508) 38127-01G11
0.30 (0.0118) 38453-01G02 6.35 (0.2500) 38127-01G12
040 (0 0157) 38453-01 G03 6.33 (0.2492) 38127-01G13
0.50 (0.0197) 38453-01G04 6.31 (0.2484) 38127-01G14

Available drive pinion bearing preload adjusting spacers

Total preload adjustment Length mm (in) Part number
Total preload 1.2- 2.3 52.20 (2.0551) 38130-78500
N·m {kg-em, in-lb) (12- 23, 10- 20)
~11
52.40 (2.0630) 38131-78500
0.13- 0.18 52.60 (2.0709) 38132-78500
Ring gear backlash mm (in) 52 80 (2.0787) 38133-78500
(0.0051- 0.0071)
53.00 (2.0866) 38134-78500 ~lF
53.20 (2.0945) 38135-78500

lila\

~'"
llilllZ
PD-99 897
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont'd)
INSPECTION AND ADJUSTMENT (R200A) Drive pinion height adjustment
Available pinion height adjusting washers
Ring gear runout
Thickness mm (in) Part number
Ring gear runout limit mm (in) 0.05 (0.0020)
3.09 (0.1217) 38154-P6017
3.12 (0.1228) 38154-P6018
Axle bearing adjustment 3.15 (0.1240) 38154-P6019
3.18 (0.1252) 38154-P6020
Axle bearing end play mm (in) 0. 0.1 (0. 0.004) 3.21 (0.1264) 38154-P6021
Available axle bearing adjusting shims 3.24 (0. 1276) 38154-P6022
3.27 (0.1287) 38154-P6023
Thickness mm {in) Part number 3.30 (0.1299) 38154-P6024
0.10 (0.0039) 38233-01G11 3.33 (0.1311) 38154-P6025
0.20 (0.0079) 38233-01812 3.36 (0.1323) 38154-P6026
0.30 (0.0118) 38233-01G13 3.39 (0.1335) 38154-P6027
0.40 (0.0157) 38233-01814 3.42 (0.1346) 38154-P6028
0.50 (0.0197) 38233-01G10 3.45 (0.1358) 38154-P6029
3.48 (0.1370) 38154-P6030
3.51 (0.1382) 38154-P6031
Side gear adjustment 3.54 {0.1394) 38154-P6032
3.57 (0.1406) 38154-P6033
Side gear backlash 3.60 (0.1417) 38154-P6034
0.10- 0.20
{Clearance between side gear 3.63 (0.1429) 38154-P6035
(0.0039. 0.0079)
and differential case) mm (in) 3 66 (0.1441) 38154-P6036
Available side gear thrust washers

Thickness mm (in) Part number Drive pinion preload adjustment

0.775 (0.0305) 38424-E3000 Drive pinion preload
0.825 (0.0325) 38424-E3001 N·m (kg-em, in-lb)
0.875 (0.0344) 38424-E3002
0.925 (0.0364) 38424-E3003 1.1 - 1.7
With front oil seal
(11- 17, 9.5- 14.8)

Available drive pinion bearing preload adjusting washers

Side bearing adjustment
Thickness mm (in) Part number
Differential carrier assembly 34.3 - 39.2
turning resistance N (kg, lb) (3.5. 4.0, 7.7. 8.8) 3.80-3.82 (0.1496- 0.1504) 38125-61001
3.82-3.84 (0.1504- 0.1512) 38126-61001
Available side bearing adjusting washers 3.84- 3.86 (0.1512- 0.1520) 38127-61001
Thickness mm (in) Part number 3.86- 3.88 (0.1520- 0.1528) 38128--61001
3.88-3.90 (0.1528- 0.1535) 38129-61001
2.00 (0.0787) 38453-N31 00 3.90- 3.92 (0.1535- 0.1543} 38130-61001
2.05 (0.0807) 38453-N3101 3.92- 3.94 (0.1543- 0.1551) 38131-61001
2.10 (0.0827) 38453-N31 02 3.94- 3.96 (0.1551- 0.1559) 38132-61001
2.15 (0.0846) 38453-N3103 3.96- 3.98 (0.1559- 0.1567) 38133-61001
2.20 (0.0866) 38453-N31 04 3.98- 4.00 (0.1567 - 0.1575) 38134-61001
2.25 (0.0886) 38453-N31 05 4.00-4.02 (0.1575- 0.1583) 38135-61001
2.30 (0.0906) 38453-N3106 4.02- 4.04 (0.1583- 0.1591) 38136-6i001
2.35 (0.0925) 38453-N31 07 4.04. 4.06 (0.1591. 0.1598) 38137-61001
2.40 (0.0945) 38453-N31 08 4.06-4.08 (0.1598- 0.1606) 38138-61001
2.45 (0.0965) 38453-N31 09 4.08-4.10 (0.1606- 0.1614) 38139-61001
2.50 (0.0984) 38453-N3110
2.55 (0.1004) 38453-N3111 Available drive pinion bearing preload adjusting spacers
2.60 (0.1024) 38453-N3112 Length mm (in) Part number

54.50 (2.1457) 38165-84000

Total preload adjustment 54.80 (2.1575) 38165-84001
55.10 (21693) 38165-84002
Total preload 1.4-3.1 55.40 (2.1811) 38165-84003
N·m (kg-em. in-lb) (14. 32, 12. 28) 55.70 (2.1929) 38165-84004
0.13-0.18 56 00 (2.2047) 38165-61001
Ring gear backlash mm (in)
{0.0051 - 0.0071)

PD-100 898
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont'd)
INSPECTION AND ADJUSTMENT (H190A) Side bearing adjustment
Ring gear runout Differential carrier assembly 34.3 - 39.2
turning resistance N (kg, lb) (3.5- 4.0, 7.7- 8.8)
Ring gear runout limit mm (in) 0.05 (0.0020)
Available side bearing adjusting shims

Thickness mm (in) Part number

Side gear adjustment
0.12 (0.0047) 38453-61201
Side gear backlash 0.15 (0.0059) 38453-61202
0.10-0.20
(Clearance between side gear 0.17 (0.0067) 38453-61203
(0.0039 - 0.0079)
and differential case) mm (in) 0.25 (0.0098) 38453-61204
Available side gear thrust washers 0.30 (0.01 18) 38453-61205
0.40 (0.0157) 38453-61206
Conventional models

Thickness mm (in) Part number Total preload adjustment

0.775 (0.0305) 38424-E3000
Total preload 1.2- 2.2
0.825 (0.0325) 38424-E3001
N·m (kg-em, in-lb) (12- 22, 10- 19)
0.875 {0.0344) 38424~E3002
0.925 (0.0364) 38424-E3003 0.13- 0.18 fEIF@
Ring gear backlash mm (in)
(0.0051 - 0.0071) li':!:
Drive pinion height adjustment
Available pinion height adjusting washers

Thickness mm (in) Part number

2.58 (0.1016) 38154-P6000

2.61 (0.1028) 38154-P6001
2.64 (0.1039) 38154-P6002
2.67 (0.1051) 38154-P6003
2.70 (0.1063) 38154-P6004
2.73 (0.1075) 38154-P6005
2. 76 (0.1 087) 38154-P6006
2. 79 (0.1 098) 38154-P6007
2.82 (0.1110) 38154-P6008
2.85 (0.1122) 38154-P6009
2.88 (0.1134) 38154-P6010
2.91 (0.1146) 38154-P6011 11iF
2.94 (0.1157) 38154-P6012
2.97 (0.1169) 38154-P6013
3.00 (0.1181) 38154-P6014
3.03 (0.1193) 38154-P6015
3.06 (0.1205) 38154-P6016
3.09 (0.1217) 38154-P6017
3.12 (0.1228) 38154-P6018
3.15 (0.1240) 38154-P6019
3.18 (0.1252) 38154-P6020

Drive pinion preload adjustment

Drive pinion preload
N·m (kg-em, in-lb}

1.1 - 1.6
With front oil seal
(11- 16, 9.5- 13.9)

PD-101 899
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont'd)
INSPECTION AND ADJUSTMENT (H233B) Drive pinion height adjustment
Available pinion height adjusting washers
Ring gear runout
Thickness mm (in) Part number
Ring gear runout limit mm (in) 0.08 (0.0031)
2.58 (0.1016) 38151-01JOO
2.61 (0.1028) 38151-01J01
Side gear adjustment 2.64 (0.1039) 38151-01J02
2.67 (0.1051) 38151-01J03
Side gear backlash 2.70 (0.1063) 38151-01J04
0.10- 0.20
(Clearance between side gear and 2.73 (0.1075) 38151-01J05
(0.0039 - 0.0079)
differential case) mm (in) 2.76 (0.1087) 38151-01J06
Available side gear thrust washers 2.79 (0.1098) 38151-01J07
2.82 (0.1110) 38151-01J08
Thickness mm (in) Part number 2.85 (0.1122) 38151-01J09
1.75 (0.0689) 38424-TSOOO 2.88 (0.1134) 38151-01J10
1.80 (0.0709) 38424-T5001 2.91 (0.1146) 38151-01J11
1.85 (0.0728) 38424-TS002 2.94 (0.1157) 38151-01J12
2.97 (0.1169) 38151-01J13
3.00 (0.1181) 38151-01J14
- Additional service for limited slip 3.03 (0.1193) 38151-01J15
3 06 (0.1205) 38151-01J16
differential model - 3.09 (0.1217) 38151-01JH
3.12 (0.1228) 38151-01J18
Differential torque adjustment 3.15 (0.1240) 38151-01J19
Differential torque 353 - 392 3.18 (0.1252) 38151-01J60
N·m (kg-m, ft-lb) (36 - 40, 260 - 289) 3.21 (0.1264) 38151-01J61
3.24 (0.1276) 38151-01J62
Number of discs and plates 3.27 (0.1287) 38151-01J63
(One side) 3 30 (0.1299) 38151-01J64
Friction disc 5 3.33 (0.1311) 38151-01J65
336 (0.1323) 38151-01J66
Friction plate 6 3.39 (0.1335) 38151-01J67
Spring disc 3.42 (0.1346) 38151-01J68
3.45 (0.1358) 38151-01J69
Spring plate 3.48 (0.1370) 38151-01J70
Wear limit of plate and disc 3.51 (0.1382) 38151-01J71
0.1 (0.004) 3.54 (0.1394) 38151-01J72
mm (in)
3.57 (0.1406) 38151-01J73
Allowable warpage of friction 0.05- 0.15 3 60 (0.1417) 38151-01J74
disc and plate mm (in) (0.0020 - 0.0059) 3.63 {0.1429) 38151-01J75
Available discs and plates 3.66 (0.1441) 38151-01J76

Plate name Thickness mm (in) Part number

1.48-1.52 38433-C6000
(0.0583 - 0.0598) (Standard type)
Friction disc
1.58- 1.62 38433-C6001
(0.0622 - 0.0638) (Adjusting type)

1.48-1.52
Friction plate 38432-C6000
(0 0583 - 0.0598)

1.48-1.52
Spring disc 38436-C6000
(0.0583 - 0.0598)
1.48- 1.52
Spring plate 38435-C6010
(0.0583- 0.0598)

PD-102 900
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont'd)
Drive pinion preload adjustment Total preload adjustment
Drive pinion preload Total preload 1.7- 2.5
N·m (kg-em, in-lb) N·m (kg-em, in-lb) (17- 25, 15- 22)

1.2- 1.5 0.15-0.20

Without front oil seal Ring gear backlash mm (in)
(12- 15, 10- 13) (0.0059- 0.0079)

Available front drive pinion bearing adjusting shims

Thickness mm (in) Part number

2.31 (0.0909) 38125-82100

2.33 (0.0917) 38126-82100
2.35 (0.0925) 38127-82100
2.37 (0.0933) 38128-82100
2.39 (0.0941) 38129-82100
2.41 (0.0949) 38130-82100
2.43 (0.0957) 38131-82100
245 (0 0965) 38132-82100
2.47 (0.0972) 38133-82100
2.49 (0.0980) 38134-82100
2.51 (0.0988) 38135-82100
2.53 (0.0996) 38136-82100
2.55 (0.1004) 38137-82100
2.57 (0.1012) 38138-82100
2.59 (0.1020) 38139-821 00

Available drive pinion bearing adjusting spacers

Thickness mm (in) Part number

4.50 (0.1772) 38165-76000

4.75 (0.1870) 38166-76000
5.00 (0 1969) 38167-76000
5.25 (0.2067) 38166-01JOO
5.50 (0.2165) 38166-0iJ10

PD-103 901