PROPELLER SHAFT &

DIFFERENTIAL CARRIER
I

SECTION PD
CONTENTS
PROPELLER SHAFT PD- 2
INSPECTION PD- 2
REMOVAL PD- 2
I NSTALLATION PD- 2
CHECKING AND CORRECTING UNBALANCED PROPELLER SHAFT PD- 2
DIFFERENTIAL CARRIER (Type R200) PD- 3
REMOVAL PD- 4
PRE-DISASSEMBLY INSPECTION PD- 4
DISASSEMBLY PD- 4
DIFFERENTIAL CASE PD- 5
INSPECTION. PD- 5
ASSEMBLY AND ADJUSTMENT PD- 6
PRECAUTIONS I N REASSEMBLY PD- 6
ASSEMBLY OF DIFFERENTIAL GEAR CASE PD- 6
ADJUSTMENT OF DRIVE PINION PRELOAD PD- 6
ADJUSTMENT OF DRIVE PINION HEIGHT PD- 7
ADJUSTMENT OF SIDE BEARING WASHERS . .. PD- 8
INSTALLATION . PD-10
REPLACEMENT OF OIL SEALS . .. PD-10
FRONT O I L SEAL .. . . PD-10
SIDE OIL SEAL PD-10
SERVICE DATA AND SPECIFICATIONS (S D S ) PD-11
SPECIAL SERVICE TOOLS PD-13
 PROPELLER SHAFT

PROPELLER SHAFT

TCompanion flange

PO427

INSPECTION 4 Draw out propeller shaft sleeve @ Propeller shaft to companion

yoke from transmission by moving flanga bolts
I Check J O U ~ M for
~ axial play If shaft rearward, passing it under rear 34-44N.m
play exists, replace propeller shaft axle (3.5.4.5 kgm,
assembly Watch for oil leakage from trans- 25 - 33 ft-lb)
mission rear end Take proper action if
Note Journal cannot be disassem- oil leak is dlscovered
bled.
Note Remove propeller shaft care-
2 Check the propeller shaft tube fully so as not to damage the splme, CHECKING AND
surface for dents or cracks If neces- sleeve yoke or rear oil seal CORRECTING UNBALANCED
sary, replace propeller shaft assembly PROPELLER SHAFT
To check and correct an unbalanc-
ed propeller shaft, proceed as follows
REMOVAL INSTALLATION 1 Remove undercoating and other
foreign material w h c h could upset
1 Raxe car on hoist To mstall, reverse the foregoing shaft balance, and check shaft nbra-
Remove front exhaust tube and removal procedure tion by road test
heat siueld plate to free them from car 2 If shaft vibration is noted during
body CAUTION: road test, disconnect propeller shaft at
2 Scribe match marks both on pro- differential carrier companion flange,
Align propeller shah with companion
peller shaft and companion flange so rotate companion flange 180 degrees
flange using reference marks prescrib-
that shaft can be reinstalled III the and reinstall propeller shaft
ed in "Remod" procedure and
anginal position 3 Again check shaft vibration If
tlghten them wlth bolts. Failure to
3 Remove bolts securing shaft t o vibration still persists, replace pro-
do so could result in driwng vibration.
companion flange peller shaft assembly

PD-2
 DIFFERENTIAL CARRIER (Type R200)

DIFFERENTIAL CARRIER (Type R200)

SPD509

PD-3
 DIFFERENTIAL CARRIER (fvoe R200)

REMOVAL DlSASSEMBLY
1 Jack u p rear of car and support 1 Put match marks on side bearing
on safety stands Drain gear od caps and carrier
2 Remove exhaust tube 2 Loosen side bearing cap bolts and
3 Disconnect propeller shaft at com- remove bearing caps
panion flange
4 Remove drive shafts
5 With differential carrier jacked up,
remove diff mounting insulator nuts
LKV38100800
6 Loosen off four fitting bolts that
SPD512
hold differential carrier onto suspen-
s o n member
7 Pull off differential carrier back- 2 Remove rear cover
ward together with jack 3 Visually inspect parts for wear or
damage
4 Rotate gears checking for any
3 Usmg Slide Hammer HT72400000
roughness w h c h would indicate dam-
lift hfferential case assembly out
aged bearings or chipped gears Check
gear teeth for scorlng or signs of
abnormal wear Measure preload of
drive pinion

SPD511

After carner assembly IS removed, PD344

support suspension member on a stand Note Care should be taken not to

to prevent its insulators being twisted confuse the left and nght hand
or damaged beanng caps and bearing outer races
PD340
SO that parts may be installed to the
Note Do not place the center of ongmal position
suspension member on the stand 5 Set up a dial indicator and check
before removal operation Other- the backlash a t several points around 4 Loosen dnve puuon nut, holdmg
wse, it wll be &fficult to extract ring gear compamon flange with Dnve Plruon
the gear carrier assembly Flange Wrench ST31520000 and pull
Ring gear-todrive pinion backlash- off companion flange usmg a suitable
0 13 - 0 18 mm Duller
(0 0051 .0 0071 in)

PRE- DISASSEMBLY
INSPECTION
Differential carrier should be in-
spected before parts except rear cover
are removed from it SPD513
These inspections are helpful in
finding the cause of the problem and 6 Check gear tooth contact with a
in determining necessary corrections m x t u r e of recommended powder and
1 Using three 45 mm ( I 77 in) Oll

spacers, mount carrier on Diff Attach- For the tooth contact pattern, see
ment KV38100800 page PD-9

PD-4
 ~
~

DIFFERENTIAL CARRIER (Tvw R200)

5 Extract drive piruon from carrier 2 Remove ring gear by loosening

using a press Take out drive pinion ring gear bolts
together with r e d bearing inner race,
bearing spacer and adjusting washer Note Loosen bolts dlagonally
6 Remove od seal
3 Punch off pinion mate shaft lock
Note Oil seal must not be reused pin from ring gear side using Sold
Punch KV3 1 100300

7 Remove pdot bearmg together

PO179 Note Lock pin is caulked at pin hole
with pdot bearing spacer and front
mouth on differential case Do not
bearing inner race using Pilot Bearing
punch it off forcibly without
Drift KV38100401
checking how it is caulked
10 To remove front and rear bear-
ing outer races, put a drift to race 4 Draw out pimon mate shaft and
KV38100401 surface, and withdraw them by t a p remove thrust block, pimon mate
ping the top of drift with a hammer gears, side gears and thrust washers
Note Put marks on gear and thrust
washer so that they can be re-
installed in theu oripnal positions
from which they were removed

INSPECTION
Thoroughly clean all disassembled
parts, and examine them to see that
P D 349 they are worn, damaged or otherwise
fdulty and how they are affected
Repdir or replace all faulty parts,
whichever is necessary
1 Check gear teeth for scoring,
cracking or chipping, and make sure
that tooth contact pattern indicates
DIFFERENTIAL CASE correct meslung depth If any damaged
part is endent, replace parts as re-
1 Extract bearing using Differential
quired
Side Bearing Puller ST3306S001 (set
of ST33051001 and ST33061000) Note. Drive pinion and drive gear are
supphed for replacement as a set,
therefore, should either part be
damaged, replace as a set

2 Check pmion mate shaft, thrust

ST
block, and pmion gears for scores and
signs of wear, and replace as required
PD348 Follow the same procedure for side
gears and their seats on differential
case
PD350
3 Inspect all bearing races and
rollers for scoring, clupping or
evldence of excessive wear They
8 Remove side od seal Note should be in tiptop condition such as
Note Oil seal must not be reused a Securely attach puller to bearing not worn and with rmrror-lke sur-
inner race, utilizing two grooves in faces Replace if there is a shadow of
9 Hold rear bearmg inner race ddferential case doubt on their efficiency, as an incor-
with Puller ST30031000 and extract b Be careful not to confuse the left rect beanng operation may result in
from drive pinion with a press and nght hand parts noise and gear seuure

PD-5
 DIFFERENTIAL CARRIER (Type R200)

4 Inspect thrust washer faces Small If above procedure is not effective Standard bearing width
damage can be corrected with sand- with existing washer, try with other 21 0 mm ( 0 827 in)
paper If pinion mate to side gear washers
backlash (or the clearance between Pinion mate gear-to-side gear
side gear and thrust washer) exceeds backlash
the specified value, replace thrust Less than 0 15 mm ( 0 0059 in)
washers
Pinion mate-to-side
gear backlash:
Less than 0 15 mm ( 0 0059 in)

5 Inspect carrier and differential

case for cracks or distortion If either
conmtion 1s evident, replace faulty PD425
parts
6 As a general rule, oil seal should
be replaced at each disassembly
.
x.f-’
-GL~: ~

PDO23
8 Press fit side bearing inner race on
differential case with Diff Side Bear-
ing Drift KV38100300 and Adapter
ASSEMBLY AND 4 Lock pinion shaft lock pin using a ST33061000
ADJUSTMENT punch after it IS secured in place
5 Apply oil to gear tooth surfaces

!ii
Assembly can be done in the re- and thrust surfaces and check that
verse order of disassembly Adherence
they turn properly KV38100300
to the following directions for ad-
justment and usage of special tools 6 Apply locktng agent [Locktite
(stud lock) or equivalent] to contact-
enable to obtain a perfect differential
ing surfaces of rmg gear and differen-
operation
tial case, then place differential case
on rmg gear
PRECAUTIONS I N
7. Apply a small amount of locktng
REASSEMBLY
agent (described above) to rmg gear PO353
1 Arrange slums, washers and the bolts, and mstall them
llke to install them correctly
2 Thoroughly clean the surfaces on CAUTION:
which shuns, washers, bearings and a. Use only genuine drive gear bolts.
bearing retainers are installed b. Tighten bolts in criss-cross fashion
3 Thoroughly clean od from rmg lightly tapping around bolt heads
gear bolt and its hole and contacting
ADJUSTMENT OF
with a hammer. DRIVE PINION PRELOAD
surfaces of rmg gear and differential
case with “Locktite Lacquic Prnner” Adjust dnve pinion preload with
o r equivalent spacer and washer between front and
4 Apply gear oil when mstalling rear bearing inner races, regardless of
beanngs thickness of pinion height adjusting
5 Pack recommended multi-purpose washer
grease mto cavity between hps when This adjustment must be carried
fitting Oseal
II out without oil seal inserted
1 Press fit front and rear bearing
ASSEMBLY OF outer races into gear carrier using
DIFFERENTIAL GEAR CASE Drive Pinion Outer Race Drift Set
ST30611000, ST30613000 and
1 Assemble pnnon mates, side gears, PD351 ST3062 1000
thrust washers and thrust block in
dlfferential case Front ST3061 1000 and
2 Fit puuon shaft to differential ST306 I3000
case so that it meets lock pin holes Rear ST3061100Oand
3 Adjust side gear-to-pinion mate 7 When replacing side bearing, ST30621000
backlash or adjust the clearance be- measure bearing width using Master
tween the rear face of side gear and Gauge KV38102000 and Weight Block 2 Insert rear bearing inner race into
thrust washer ST32501000 prior to installation Dummy Shaft KV38100110

PD-6
 DIFFERENTIAL CARRIER (Type R200)

3 Fit drive pinion bearing spacer, H a g h i gduge (KV3810012?) Set number

washer front bearing inner race, Dum- Hcad
my Shaft Collar KV38100130 and number
companion flange in that order on (HI
dummy shaft and tighten drive pinion
nut with Stopper KV38100140 PO186
A
Drive pinion nut
186 -216 N rn
(19.22 kgm,
137 - 159 ft-lb)
Examples of calculation
rKV38100 I 4 0
Ex 1 -..
N = 0 23 mm
H=t2, D = 1

T =N-[(H-D')xO01]+300
= 0 23 - [((t2) - 1) x 0 01 ]
+ 3 00
PD355 = 0 2 3 - [(2 - 1 ) x 0011 t 3 00
4 Measure pinion bearlng preload =023-[1x001]+300
using Preload Gauge ST3127S000, and 2 Measure the clearance (N) be- = 0 23 - 0 01 + 3 M)
select washer and spacer that WIN tween the tip end of height gauge and =322mm
provide required preload the end surface of dummy shaft, using The correct washer IS 3 21 mm
a thickness gauge thick
Pinion bearing preload
(without oil seal)
1.0.1 3 N m
(10 - 13 kgcm, Ex 2 --.
8 7 . 11 3 in-lb)
N=03Smm
Note H=-1, D'=2
a Replace beanng washer and spacer T = N - [(H-D')xOOl] t 3 0 0
with thicker ones if pinion cannot = 0 35 - [((-I) - 2) x 0 011
be turned by hand while it is being t 3 00
tightened =03S-[(-1-2)~001]
b Reload of old beanng is the same + 3 00
d u e as that of a new bearing = 0 3s - [(-3) x 0 011 t 3 00

3 The thckness of drive p m o n =035-[-003]+300

height adlusting washer can be ob- = o 3s t 0 0 3 t 3 00
tamed from the followmg formula = 3 38
T=N-[(H-D')xOOl] +3M) The correct washer IS 3 39 mm
thick

Where, Ex 3 -..
T Required thickness of rear bear-
ing adlusting washers (mm) N = O 27 mm
N Measured value with ttuckness H=O, D'=O
ADJUSTMENT OF gauge (mm) T = N - [(H-D')xOOl] +300
DRIVE PINION HEIGHT H Figure marked on the drive = 0 2 7 - [(0-O)xOO1]
pinion head f 3 00
Adjust pinion height with washer D Figure marked on the dummy
located between rear bearing inner =027- [OxOOI] t300
shaft = 0 2 7 - 0 t 300
race and back of pinion gear
Note Figures for H and D are dimen- = 3 27
1 Install Height Gauge sional vanations in a unit of 1/100
KV38100120 on carrier with dummy mm (4/10,000 m) agdmst each The correct washer is 3 27 m m
shaft mounted standard measurement ttuck

PD-7
 DIFFERENTIAL CARRIER (Type R200)

Note If values sigrufying H and D' are ADJUSTMENT OF SIDE

not given, regard them as zero and BEARING WASHERS
compute After assembly, check to 1 If the hypoid gear set, carrier,
see that tooth contact is correct If differential case or side bearing has
not, readjust been replaced with new part, adjust
For the tooth contact pattern, see
the side bearing preload with adjusting
page PD-9 washer The required thicknesses of
the left and nght washers can be
Note P h o n height adjustment can
obtained from the following formulas
be made in a u t of 1/1m mm
(4/10,000 m) by s e l e a h g d m T, = ( A - C + D - H ) x O O l + E + 2 0 5
0 05 mm (0 0020 in) o r 0.07 mm T2 = ( B - D t H') x 0 01 t F + G + I 95
(0 0028 in) s h m in above chart
Where,
4 Fit determined pinion height ad- T i Required thickness of left side
justing washer in drive pinion, and washer (mm)
press fit rear bearing inner race in it T2 Required thicknes of right side
using Base ST30901000 washer (mm)
A & B Figure marked on the gear
carrier
C & D Figure marked on the differ- Sei number Varlanon number (H)
ential case
E & F These are differences in width
ST3090 1000 of left or right side bearing against
the standard width (21 00 mm)
If bearing width is 20 82 mm, this
figure wlll he as follows
PO190
21 00 - 2 0 8 2 = O 18 (mm)
Example of calculation
PO092 G This is the difference in thickness
Note Insert washer mto pinion with
of side spacer against the standard Ex 1 --
width (8 10 mm) If spacer width is A=4, B=3, C = 5 , D = 6
the chamfered side towards gear
8 02 mm, this figure wdl be as E=O18mm, F = O l S m m
5 Lubricate pinion front and rear follows G = O 0 8 m m , H'=-2
beanngs Install dnve pinion in gear H Figure marked on rmg gear
carrier into which drive pinion bearing 8 10 - 8 02 = 0 08 (mm) Left side
spacer and vasher, front bearing inner Figures for A, B, C and D are Ti = ( A - C t D - H ) x 0 0 l + E
race and front pllot bearing spacer, dimensional variations m a unit of t205
moreover, pllot bearing and front oll l/loO mm against each standard meas- -- [ 4 - 5 + 6 - ( - 2 ) j ~ 0 0 1
seal are fitted Fit front OII seal using urement + 0 18 + 2 OS
Gear Carrier Front Oil Seal Drift To measure width of side bearing, = 7 x 001 + O 18 + 2 05
KV38 100500 see differential case assembly pro- = 007 t 0 18 + 2 05
6 Fit companion flange on drive cedure = 2 30
pinion, and secure it in position by Before calculation, deterrmne "G"
tightening n u t to specified torque con- The correct washer IS 2 30 mm
value by measurmg spacer thxkness If thck
firming preload spacer is deformed or scratched, re-
Note If dnve pimon lock nut IS worn, place h g h t side
replace it T, = (B - D t H ) x 0 01 t F + G
@ : Drive pinion nut t 195
-- 1 3 - 6 + ( - 2 ) ] xOOltO15
186 - 216 N rn
(19.22 kgm, + 0 08 + I 95
137.159 ft-lb) =(-5) x 001 + O IS t 008
Drive pinion preload + 195
(with oil real) =-005 + O 15 + 0 0 8 + 1 9 5
1.13 - 1.72 N.m =213
(11.5.17.5 kgcm, The correct wpsher IS 2 15 mm
10 0 - 15.2 in-lb) Uuck

PD-8
 DIFFERENTIAL CARRIER (Type R200)

Ex 2 .-- Note When driving spacer into place, 7 Check and adjust the tooth con.
be careful not to tilt side bearing tact pattern of ring gear and drive
A=6, B=6, C = 5 , D = 3 pinion
outer race to either side
E=O17mm, F-022mm
(I) Thoroughly clean ring and drive
G=OIOmm, H'=2 5 Align mark on bearing cap with pinion gear teeth
that on carrier and install bearing cap (2) Paint ring gear teeth lightly and
Left side
on Larrier And tighten bolts to speci- evenly with a mixture of powdered
T i = ( A - C t D - H') x 001 + E fied torque ferric oxide and oil of a suitable con-
+ 2 05 sistency to produce a contact pattern
@ Side bearing cap bolts
= ( 6 - 5 t 3 - 2) x 0 0 1 t 0 I 7 88-98Nm (3) Rotate pinion through several
+ 2 05
(9 0 . 1 0 0 kg-m. revolutions in the forward and reverse
= 2 x 001 + O 17 t 2 05 65 - 72 ft-lb) direLtion until a definite contact pat-
= 0 02 t 0 I 7 + 2 05
tern is developed on ring gear
= 2 24
(4) If contact pattern is incorrect,
The correct washer is 2 25 mm readjust thickness of adjusting washer
thck Be sure to completely wipe off red
f i g h t side lead upon completion of adjustment
( 5 ) Incorrect teeth contact pattern
T, = ( B - D t H')x 0 0 1 f F + G
'an be adjusted in the following
t 195
manner
= (6 - 3 t 2) x 001 f 0 22
+010+195
= 5 x 0 01 + 0 22 + 0 IO
PD362
t 195
= 0 0 5 + 0 2 2 t O I O + 195
= 2 32
The correct washer is 2 30 mm
thick 6 Measure ring gear-to-drive pinion
backlash with a dial indicator Contact pattern
Note If values signifying A, B C and If it IS below the specified value,
Dare not gwen, regard them as zero replace left washer with a thinner one a Heel contact
and compute T o correct, increase thickness of
and right washer with a thicker one If
After assembly, check to see that it is over i t , replace left washer with a pinion height adjusting washer in order
preload and backlash are correct If ttucker one and right washer with a to bring drive pinion close to ring gear
not, readjusl thinner one
2 Install differential case assembly
Note To maintain correct preload at
with side bearing outer races into
all tunes, d o not change total thick-
carrier
ness of washers
3 Insert left and right side bearing
preload adjusting washers in place be. Ring gear-todrive pinion backlash
tween side bearings and hocsing 0.13.0.18 mm
PO193
4 Drive in side bearing spacer be (0.0051 .0.0071 in)
tween R H washer and housmg with
Side Bearing Spacer Drift
KV38100600 If too great or too small b Toecontact
a dnving force is required, check to be To correct, reduce thickness of
sure that calculation and side bearing pinion height adjusting washer in order
width are correct to make drive pinion move away from
ring gear

SPD513

Incidentally a decrease or increase

in thickness of washers causes change
in ring gear-to-pinion ba( klash
PD194
Thus, check for proprr backldsh

PD-9
 DIFFERENTIAL CARRIER (Type R200)

c Flankcontact INSTALLATION FRONT OIL SEAL

Adjust in the same manner as in b
Install in the reverse order of re. Procedures are as follows
moval 1 Dram gear oil
1 Position differential carrier onto 2 Raise vehicle on hoist
suspension member, and temporarily 3 Remove insulator, exhaust tube
tighten it with four bolts and main muffler mounting bolt to
2 Fit rear cover to mounting insula- free them from car body
tor nuts 4 Detach propeller shaft
PO195 @ Rear cover to mounting 8 Remove drive piruon nut
insulator nuts 6 Extract comparuon flange with a
d Face contact suitable puller
98.118 N m
Adjust in the same manner as in a (10 0 - 12 0 kg-m, 7 Remove oil seal
7 2 . 8 7 ft-lbl 8 Set new oil seal in position with
Mounting insulator to body Gear Carner Front Oil Seal Dnft
Bolt KV38100800 Apply grease to canty
29.39 N m between seal lips
( 3 . 4 kg-m, 9 Fit companion flange on dnve
2 2 . 2 9 ft-lbl pinion, and secure it in position by
Nut tightening nut to specified torque con-
PD196 5 9 -78 N m firming the following preload, with
( 6 . 8 kg-m, Drive Pinion Flange Wrench
e Correct tooth contact 43.58 ft-lb)
0.
Drive pinion nut
186 - 216 N.m
3 Secure differential carrier onto (19122 kg-m,
rear suspension member with four 137 - 159ft-lb)
bolts Total preload
@ Differentlal carrier to 123 - 230 N m
suspension member bolts (12 5 - 23 5 kgcm,
. PD197
59 - 7 8 Nm
(6 0 .8.0 kg-m,
90. 170 in-lbl
10 Reinstall propeller shaft in re-
43 - 58 ft-lbl verse order of removal, and fill up with
Note Change m thickness of adjust- gear oil
ing washer is accompamd by 4 Install drive shaft
change in backlash Check it when 8 Join drive shafts with comparuon
installing gear flanges of rear axle shafts and tighten SIDE OIL SEAL
connectmg bolts Side od seal is replaced as follows
8 Install rear cover 0 .Drive shaft to axle shaft bolts 1 hsconnect drive shafts
@ Rear cover attaching bolts 27 - 37 N m 2. Remove od seal
(2 8 - 3.8 kg-m, 3 Set in new OIIseal with Gear
16 - 24 N m
(1 6 - 2.4 kg-m, 20 .27 ft-lb) Carrier Side 011 Seal Drift
12.17 ft-lb) KV38100200
6 Install other parts in the reverse
manner of removal Note Apply grease to cavity between
9 Apply grease to cavity at sealing oil seal IIps
lips of od seal 7 FIU with correct gear od
Press side od seal into carrier with Note Gear oil capaclty 4 Install drive shafts
Gear Carrier Side Od Seal Drift 1.3liter(2-3/4USpt,2-1/4Imp pt) Note Be careful not to scratch oil
KV38 100200 seal lips with sphne of drive shaft.
0: Drive shaft to axle shaft bolts
VG30E without turbo
39 - 49 N.m
(4.5 kg-m,
REPLACEMENT OF 29 - 36 ft-lb)
OIL SEALS VG3OE turbo
Replacement of od seals with dif- 59.69 N m
ferential gear carrier assembly mstalled -
(6 7 kg-m,
PO363 on the velucle 43 - 51 ft-lb)
 SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Propeller Shaft

GENERAL SPECIFICATIONS Unit mm On1

2 seatei I 2+2 seater

Applied model VG30E wthout turbo VG30E turbo VG30E without turbo VG30E turbo

MIT AIT M/T AIT MIT Am MIT A/T

Propeller shaft model ZS71A

Number Of Joints I 2

Couplmg method with t r a k s i o n I Sleeve type

Dlrtance between yokes I 71 12 80)

Type of journal bearing Shell type lnon-dlrarrembly type)

Shaft length (Spider to rpiderl 665 126 181 685 126 97) 650 (25 591 715 I28 151 865 134 061 885 (34 84) 850 133 461 915 136 02)

Shaft outer diameter I 75 12 951

SERVICE DATA
Unit mm (cnl TIGHTENING TORQUE
~~~ ~ ~

Model 2S71A U"lt Nm kg-m ft-lb

Propeller shaft runout llmlt 0 6 I O 0241 Shaft t o Companion 39-44 40-45 29 33

flange bolts
Journal axial Play 0 101

Differeni 11 Carrier

GENERAL SPECIFICATIONS SERVICE DATA

Final drive model WOO
wthout turbo
D r ~ v eptnion beartog preload
F~nald w e model
~ ~~
I ~
R200 adjusting method
Adiumng spacer and washer

Ring gear pitch Drwe p m o n preload

mm I n ) 200 (7 871 1 13.1 72
diameter IWlth front 011seal1
(115-175,100-1521
N m l k g i m , In-lbl
Gear ratio 3 700 3 545
Drive pinion preload
Number of teeth IWithout front 011real) 1 0 - 1 3 (10- 13,s 7 - 11 31
37/10 39111
[Ring gear1Drwe p m o n l N m I k g i m . in-lbl
-
011 capacity lapprox 1 Total preload 1 23 - 2 30
1 3 12-3/4, 2-1/41
Q IUS P Z , Imp gtl N m Ikgcm, d b l I12 5 - 23 5. 10 9 - 2041
-
Side bearing adJustmgmethod Shim

Backlash
Drive pinIan t o ring gear
0 13.0 18 10 0051 - 0 00711
rnm I i n l

Side gear t o pinion mate gear

(Clearance between ride gear Less than 0 15 (000591
to differential carel mm I d
~ ~

Ring gear runout Imit mm I i n l Less than 0 08 IO 00311

PD-11
 SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Differential c rrier (Cont'd)

Pinion height adjusting washer Side bearing adjusting washer

Thickness mm l i n l Part No Thickness m m l > n l Part No

3 09 IO 12171 38154.P6017 2 00 I O 07871 38453-N3100

3 12 10 1228) 38154P6018 2 05 I O 08071 38453-N3101
3 15 (0 1240) 38154.P6019 2 10 (008271 38453.N3102
3 18 I O 12521 38154P6020 2 15 I O 08461 38453-N3103
3 21 IO 12641 38154.P6021 2 20 10 08661 38453-N3104
3 24 10 1276) 38154-P6022 2 25 I O 08861 38453.N3105
3 27 (0 12871 38154.P6023 2 30 I O 09061 38453.N3106
3 30 I O 12991 38154-P6024 2 35 I O 09251 38453 N3107
3331013111 38154-P6025 2 40 10 09451 38453-N3108
3 36 IO 1323) 38154-Pti026 2 45 I O 09651 38453.N3109
3 39 IO 13351 38154.P6027 2 50 10 09841 38453.N3110
3 42 10 13461 381 54-P6028 2 55 10 10041 38453.N3111
3 45 IO 1358) 38154.P6029 2 60 I O 10241 38453-N3112
3 48 (013701 38154-P6030
3 51 10 13821 381 54 P6031 Side gear thrust washer
3 54 IO 13941 38154-P6032 ~ ~~

3 57 IO 14061 38154P6033 Thickness mm lint Part No

3 60 (01417) 38154.P6034
3 63 IO 14291 38154.P6035 0 75.0 80 I O 0295.0 0315) 38424.N3100
3 66 (01441) 38154-P6036 080-085100315-003351 38424-N3101
0 05 10 00201 38453-28500 0 8 5 . 0 90 IO 0335.0 0354) 38424-N3102
0 07 (000281 38454-28600 0 9 0 . 0 95 I O 0354 - 0 03741 38424.N3103

TIGHTENING TORQUE
Type R200

Unlt Nm kg-m ft-lb

Drive pinion bearing preload adjusting washer
Final drive installation
Thlcknerr mm (In1 Part No
Drive shaft to rear axle
3 80 - 3 82 10 1496 - 0 15041 3812561001 VG30E without 39.49 4-5 29.36
3 82.3 84 10 1504- 0 15121 38126-61001 turbo
3 8 4 . 3 86 I O 1512 - 0 15201 38127-61001 VG30E turbo 59-69 6-7 43 - 51
3 8 6 . 3 88 (0 1 5 2 0 - 0 1528) 381 2 8 6 1001 Rear cover to 88-118 90-120 65-87
3 88 - 3 90 10 1 5 2 8 - 0 15351 3812961001 mounting lniulator
390-392101535-01543) 38130-61001
Mounting insulator
3 9 2 . 3 94 (01543 - 0 15511 38131-61001
to body
-
3 94 3 96 10 1551 .O 15591 3813261001
Bolt 29-39 3 4 -
22 29
3 9 6 . 3 98 IO 1 5 5 9 - 0 15671 3813361001
Nut 59-78 6-8 43.58
-
3 98 4 00 IO 1567 - 0 15751 38134-61001
4 00 - 4 02 I O 1 5 7 5 - 0 1583) 3813561001 Dlfferentjal carrier to 59 78 6.8 43.58
- -
4 02 4 04 10 1583 0 15911 3813661001 suspension member
4 0 4 - 4 06 I O 1591 - 0 1598) 3813761001
Final drive assembly
-
4 06 4 0 8 I O 1 5 9 8 - 0 16061 38138-61001
408-410101606-01614) 38139-61001 Drive p t n m nut 186-216 19-22 137 - 159
Ring gear bolt [using
Locktite lrtud lock1 or
equivalent1
VG30E without 69 - 78 7 0.8 0 51 .58
turbo
Drive pinion bearing preload adjusting spacer VG30E turbo 88-98 90-100 65-72
Side bearing cap bolt 88 - 98 9 0.10 0 65 - 72
Length mm Id Part No
Rear cover fixing bolt 16. 24 16-24 12-17
55 10 ( 2 16931 3816564002
Companm flange to 39.44 40-45 29-33
55 40 I2 181 11 38165-64003
propeller shaft fixing
55 70 I2 1929) 3816584004
bait
56 00 I2 2047) 38165-61001
56 25 I2 21461 3816661001 Filler and drat" plug 59 - 98 6 - 10 -
43 7 2

PD-12
 SPECIAL SERVICE TOOLS

Tool number
(Kent-Moore No 1 Tool name

ST30611000 Drift
(J25742-1)

~~ ~

ST30613000 Drift
lJ25742-3)

ST30621000 Drift
( - )

ST3090SOOO Drive pinion rear bearing

inner race puller set
P
@ ST30031000 Puller
(J22912-011
@ ST30901000 Base
( - 1

ST3127S000 Preload gauge

(J25765-A)
@ GG91030000 Torque wrench
(J25765-A)
@ HT62940000 Socket adapter -3
( - 1
@ HT62900000 Socket adapter
( - 1
~ ~~

ST31 520000 Drive pinion flange wrench

( - 1

ST32501000 Weight block

(J25407.3)

ST3306SJ01 Diff side bearing puller set

@ST33051 001 Body
1 - 1
@~T33061000 Adapter
(58107-21

PD-13
 SPECIAL SERVICE TOOLS

Tool number
Tool name
(Kent-Moore No )

KV38100800 Diff attachment

( - )

KV31100300 Solid punch

(J25689-A)

KV38100200 Gear carrier side oil seal drift

KV381001 SO Drive pinion setting gauge set

(R200)
@ KV38100110 Dummy shaft
( - )
@ KV38100120 Height gauge
( - )
@ KV38100130 Collar
( - 1
@ KV38100140 Stopper
( - )

KV38100300 Diff side bearing d r i f t

(J25523)

KV38 100401
( - 1

KV38100500 Gear carrier front oil seal drift

( - )

KV38100600 Side bearing spacer drift

(J25267)

57
PD-14
 SPECIAL SERVICE TOOLS

Tool number
Tool name
(Kent-Moore No 1

KV38102000 Master gauge

[21 0 mrn (0827 in11

PD-15
~