DIFFERENTIAL CARRIER (Type R200)
4 Inspect thrust washer faces Small
damage can be corrected with sand-
paper If pinion mate to side gear
backlash
(or the clearance between
side gear and thrust washer) exceeds
the specified value, replace thrust
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
parts
6 As
a general rule, oil seal should
be replaced at each disassembly
ASSEMBLY AND
ADJUSTMENT
Assembly can be done in the re-
verse order of disassembly Adherence
to the following directions for ad-
justment and usage of special tools
enable to obtain a perfect differential
operation
PRECAUTIONS IN
REASSEMBLY
1 Arrange slums, washers and the
llke to install them correctly
2 Thoroughly clean the surfaces
on
which shuns, washers, bearings and
bearing retainers are installed
3 Thoroughly clean od from rmg
gear bolt and its hole and contacting
surfaces of rmg gear and differential
case with “Locktite Lacquic Prnner”
or equivalent
4 Apply gear oil when mstalling
beanngs
5 Pack recommended multi-purpose
grease mto cavity between hps when
fitting
OII seal
ASSEMBLY OF
DIFFERENTIAL GEAR CASE
1 Assemble pnnon mates, side gears,
thrust washers and thrust block in
dlfferential case
2
Fit puuon shaft to differential
case
so that it meets lock pin holes
3 Adjust side gear-to-pinion mate
backlash or adjust the clearance be-
tween the rear face of side gear and
thrust washer
If above procedure is not effective
with existing washer, try with other
washers
Pinion mate gear-to-side gear
backlash
Less than 0 15 mm (0 0059 in)
-GL~: ~ . x.f-’
PDO23
4 Lock pinion shaft lock pin using a
punch after it
IS secured in place
5 Apply oil to gear tooth surfaces
and thrust surfaces and check that
they turn properly
6 Apply locktng agent [Locktite
(stud lock) or equivalent] to contact-
ing surfaces of rmg gear and differen-
tial case, then place differential case
on rmg gear
7. Apply a small amount of locktng
agent (described above) to rmg gear
bolts, and mstall them
CAUTION:
a.
Use only genuine drive gear bolts.
b. Tighten bolts in criss-cross fashion
lightly tapping around bolt heads
with a hammer.
PD351
7 When replacing side bearing,
measure bearing width using Master
Gauge KV38102000 and Weight Block
ST32501000 prior to installation
PD-6
Standard bearing width
21 0 mm (0 827 in)
PD425
8 Press fit side bearing inner race on
differential case with Diff Side
Bear-
ing Drift KV38100300 and Adapter
ST33061000
KV38100300 !ii
PO353
ADJUSTMENT OF
DRIVE PINION PRELOAD
Adjust dnve pinion preload with
spacer and washer between front and
rear bearing inner races, regardless of
thickness of pinion height adjusting
washer
This adjustment must be carried
out without
oil seal inserted
1 Press fit front and rear bearing
outer races into gear carrier using
Drive Pinion Outer Race Drift Set
ST30611000, ST30613000 and
ST3062
1000
Front ST3061 1000 and
Rear ST3061100Oand
ST306 I3000
ST30621000
2
Dummy Shaft KV38100110
Insert rear bearing inner race into
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No 1
ST30611000
(J25742-1)
ST30613000
lJ25742-3)
ST30621000
(-)
ST3090SOOO
@ ST30031000
(J22912-011
@ ST30901 000
(-1
ST3127S000
(J25765-A)
@ GG91030000
(J25765-A)
@ HT62940000
(-1
@ HT62900000
(-1 ~ ~~
ST31
520000
(- 1
ST32501000
(J25407.3)
ST3306SJ01
@ST33051
001 1-1
@~T33061000 (58107-21
Tool name
Drift ~~ ~
Drift
Drift
P Drive pinion
rear bearing
inner race puller set
Puller
Base
Preload gauge
Torque wrench
Socket adapter -3
Socket adapter
Drive pinion flange wrench
Weight block
Diff side bearing puller set
Body
Adapter
PD-13
