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D DRIVELINE/AXLE

B
SECTION
REAR FINAL DRIVE C

RFD

E
CONTENTS
C200 LSD) .................................................................... 31 F
INSTALLATION OF DRIVE PINION ASSEMBLY... 34
PREPARATION ........................................................... 3 INSTALLATION OF DIFFERENTIAL CASE ........ 36
Special Service Tools ............................................... 3 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 38 G
NOISE, VIBRATION, AND HARSHNESS (NVH) C200 ....................................................................... 38
TROUBLESHOOTING ................................................ 6 GENERAL SPECIFICATIONS ............................. 38
NVH Troubleshooting Chart ..................................... 6 RING GEAR RUNOUT ........................................ 38
FRONT OIL SEAL ...................................................... 7 H
SIDE GEAR ADJUSTMENT (WITHOUT LSD) ... 38
Removal and Installation .......................................... 7 SIDE BEARING ADJUSTMENT .......................... 39
REAR COVER GASKET ............................................ 9 TOTAL PRELOAD ADJUSTMENT ...................... 39
Removal and Installation .......................................... 9 DRIVE PINION HEIGHT ADJUSTMENT ............ 39 I
REAR FINAL DRIVE ASSEMBLY ............................ 10 DRIVE PINION PRELOAD ADJUSTMENT ......... 39
Removal and Installation ........................................ 10 DIFFERENTIAL TORQUE ADJUSTMENT
REMOVAL ........................................................... 10 (WITH LSD) ......................................................... 39 J
INSTALLATION ................................................... 10
Components ............................................................11
Pre-Inspection ........................................................ 14
H233B
TOTAL PRELOAD ............................................... 14 K
PREPARATION ......................................................... 41
RING GEAR-TO-DRIVE PINION BACKLASH ... 14 Special Service Tools ............................................. 41
RING GEAR RUNOUT ........................................ 14 NOISE, VIBRATION, AND HARSHNESS (NVH)
TOOTH CONTACT .............................................. 14 TROUBLESHOOTING .............................................. 44 L
SIDE GEAR-TO-PINION MATE GEAR BACK- NVH Troubleshooting Chart ................................... 44
LASH ................................................................... 15 FRONT OIL SEAL ..................................................... 45
Disassembly and Assembly ................................... 15 Removal and Installation ........................................ 45 M
REMOVAL OF DIFFERENTIAL CASE ............... 15 REAR FINAL DRIVE ASSEMBLY ............................ 47
REMOVAL OF DRIVE PINION ASSEMBLY ....... 16 Removal and Installation ........................................ 47
DISASSEMBLY OF DIFFERENTIAL CASE REMOVAL ........................................................... 47
(WITHOUT LSD) ................................................. 17 INSTALLATION ................................................... 47
DISASSEMBLY OF DIFFERENTIAL CASE Components ........................................................... 48
(WITH LSD) ......................................................... 19 Pre-Inspection ........................................................ 49
INSPECTION ...................................................... 20 TOTAL PRELOAD ............................................... 49
ADJUSTMENT OF DIFFERENTIAL CASE RING GEAR TO DRIVE PINION BACKLASH ..... 49
(WITH LSD) ......................................................... 22 RING GEAR RUNOUT ........................................ 49
SIDE BEARING PRELOAD ................................ 23 TOOTH CONTACT .............................................. 50
PINION GEAR HEIGHT ...................................... 25 SIDE GEAR TO PINION MATE GEAR BACK-
TOOTH CONTACT .............................................. 29 LASH ................................................................... 50
ASSEMBLY OF DIFFERENTIAL CASE (WITH- Disassembly and Assembly .................................... 50
OUT LSD) ........................................................... 30 REMOVAL OF DIFFERENTIAL CASE ASSEM-
ASSEMBLY OF DIFFERENTIAL CASE (WITH

RFD-1
BLY ...................................................................... 50 LSD) .....................................................................65
REMOVAL OF DRIVE PINION ASSEMBLY ........ 51 INSTALLATION OF DRIVE PINION ASSEMBLY...67
DISASSEMBLY OF DIFFERENTIAL CASE INSTALLATION OF DIFFERENTIAL CASE ........69
(NON LSD) .......................................................... 53 SERVICE DATA AND SPECIFICATIONS (SDS) ......71
DISASSEMBLY OF DIFFERENTIAL CASE General Specifications ............................................71
(WITH LSD) ......................................................... 54 2WD MODEL .......................................................71
INSPECTION ....................................................... 56 4WD MODEL .......................................................71
ADJUSTMENT OF DIFFERENTIAL CASE Ring Gear Runout ...................................................71
(WITH LSD) ......................................................... 58 Side Gear Adjustment .............................................71
PINION GEAR HEIGHT ...................................... 59 Differential Torque Adjustment (LSD Models) .........71
TOOTH CONTACT .............................................. 63 Total Preload Adjustment ........................................72
ASSEMBLY OF DIFFERENTIAL CASE (NON Drive Pinion Height Adjustment ..............................72
LSD) .................................................................... 64 Drive Pinion Preload Adjustment ............................73
ASSEMBLY OF DIFFERENTIAL CASE (WITH

RFD-2
PREPARATION
[C200]
PREPARATION PFP:00002
A
Special Service Tools EDS0012P

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
B
(Kent-Moore No.) Description
Tool name
ST3127S000 Measuring pinion bearing preload and total
(See J25765-A) preload C
Preload gauge
1 GG91030000
(J25765)
Torque wrench
RFD
2 HT62940000
( — )
Socket adapter E
3 HT62900000 NT124

( — )
Socket adapter
KV38108300 Removing and installing propeller shaft lock F
(J44195) nut and drive pinion lock nut
Companion flange wrench
G

NT771
H
ST3090S000 Removing and installing drive pinion rear in-
( — ) ner cone
Drive pinion rear inner race puller set a: 79 mm (3.11 in) dia.
1 ST30031000 b: 45 mm (1.77 in) dia. I
(J22912-01) c: 35 mm (1.38 in) dia.
Puller
2 ST30901000
J
(J26010-01)
NT527
Base
ST3306S001 Removing and installing differential side bear-
Differential side bearing puller set ing inner cone K
1 ST33051001 a: 28.5 mm (1.122 in) dia.
(J22888-20) b: 38 mm (1.50 in) dia.
Body
L
2 ST33061000
(J8107-2)
Adapter NT072

ST33230000 Installing side bearing inner cone M


(J25805-01) a: 51 mm (2.01 in) dia.
Differential side bearing drift b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.

NT085

ST33081000 Installing side bearing inner cone and remov-


( — ) ing and installing differential case couple
Side bearing puller adapter bolts·
a: 43 mm (1.69 in) dia.
b: 33.5 mm (1.319 in) dia.

NT073

RFD-3
PREPARATION
[C200]
Tool number
(Kent-Moore No.) Description
Tool name
KV38100600 Installing side bearing spacer
(J25267) a: 8 mm (0.31 in)
Side bearing spacer drift b: R42.5 mm (1.673 in)

NT528

ST30611000 Installing pinion rear bearing outer race


(J25742-1)
Drift

NT090

ST30621000 Installing pinion rear bearing outer race


(J25742-5) a: 79 mm (3.11 in) dia.
Drift b: 59 mm (2.32 in) dia.

NT073

ST30613000 Installing pinion front bearing outer race


(J25742-3) a: 72 mm (2.83 in) dia.
Drift b: 48 mm (1.89 in) dia.

NT073

KV38100500 Installing front oil seal


(J25273) a: 85 mm (3.35 in) dia.
Gear carrier front oil seal drift b: 60 mm (2.36 in) dia.

NT115

(J34309) Adjusting bearing pre-load and gear height


Differential shim selector

NT134

(J25269-4) Selecting pinion height adjusting washer


Side bearing discs
(2 Req'd)

NT136

RFD-4
PREPARATION
[C200]
Tool number
(Kent-Moore No.) Description A
Tool name
(J8129) Measuring carrier turning torque
Spring gauge B

NT127

KV381051S0 Checking differential torque on limited slip dif- RFD


( — ) ferential
Rear axle shaft dummy
1 KV38105110
( — ) E
Torque wrench side
2 KV38105120
( — )
NT142
Vise side F
KV10112100 Tightening side bearing cap bolts
(BT8653-A)
Angle wrench G

H
S-NT014

RFD-5
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
[C200]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003

NVH Troubleshooting Chart EDS0012Q

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

FAX-4,RAX-5 , FSU-4 , RSU-4


RFD-21 , RFD-21

RFD-20

RFD-20

RFD-14

MA-12

RAX-5
WT-3
PR-3

BR-6

PS-5

Reference page

Companion flange excessive runout

AXLE AND SUSPENSION


Improper gear contact

PROPELLER SHAFT
Tooth surface worn
Possible cause and SUSPECTED PARTS

Incorrect backlash
Rough gear tooth

Improper gear oil

ROAD WHEEL

DRIVESHAFT

STEERING
BRAKES
TIRES
Symptom DIFFERENTIAL Noise × × × × × × × × × × × × ×
×: Applicable

RFD-6
FRONT OIL SEAL
[C200]
FRONT OIL SEAL PFP:38189
A
Removal and Installation EDS0012R

1. Remove propeller shaft. Refer to PR-8, "Removal and Installation" .


2. Loosen drive pinion nut while holding companion flange using B
Tool.
Tool number : KV38108300 (J-44195)
C

RFD

APD032 E

3. Remove companion flange using a suitable tool.


4. Remove ABS sensor and rear wheel sensor rotor.
F

SPD737

5. Remove front oil seal. I

L
WPD013

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


Press front oil seal into carrier using Tool. M
Tool number : KV38100500 (J25273)
7. Install ABS sensor and rear wheel sensor rotor.
ABS sensor : 18 - 24 N·m (1.8 - 2.4 kg-m,
bolts 13 - 17 lb-ft)
8. Install companion flange.

WPD014

RFD-7
FRONT OIL SEAL
[C200]
9. Hold the companion flange using Tool and tighten drive pinion
nut.
Tool number : KV38108300 (J-44195)

Drive pinion : 127 - 294 N·m (13 - 30 kg-m,


nut 94 - 217 ft-lb)

APD032

10. Install rear propeller shaft. Refer to PR-8, "Removal and Installation" .

RFD-8
REAR COVER GASKET
[C200]
REAR COVER GASKET PFP:38320
A
Removal and Installation EDS0012S

1. Drain gear oil. Refer to MA-40, "Changing Differential Gear Oil" .


2. Remove rear cover and rear cover gasket. B
3. Install new rear cover gasket and rear cover.
4. Tighten rear cover bolts.
C
Rear cover bolts : 44 - 54 N·m (4.5 - 5.5 kg-m,
33 - 39 ft-lb)
5. Fill final drive with recommended gear oil. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRI- RFD
CANTS" .

RFD-9
REAR FINAL DRIVE ASSEMBLY
[C200]
REAR FINAL DRIVE ASSEMBLY PFP:38300

Removal and Installation EDS0012T

REMOVAL
CAUTION:
● Be careful not to damage spline, sleeve yoke and front oil seal when removing propeller shaft.
● Before removing the final drive assembly or rear axle assembly, disconnect the ABS sensor har-
ness connector from the assembly and move it 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 inopera-
tive.
1. Remove propeller shaft. Refer to PR-8, "Removal and Installation" .
● Plug front end of transfer.

2. Remove axle shaft. Refer to RAX-8, "Removal" .


INSTALLATION
● Installation is in the reverse order of removal.
● Fill final drive with recommended gear oil to the specified level
shown. Refer to MA-39, "Checking Differential Gear Oil" .

SPD123

RFD-10
REAR FINAL DRIVE ASSEMBLY
[C200]
Components EDS0012U

RFD

LDIA0019E

RFD-11
REAR FINAL DRIVE ASSEMBLY
[C200]
1. Axle case 2. Front oil seal 3. ABS sensor unit
4. Rear wheel sensor rotor 5. Companion flange 6. Inner cone
7. Outer race 8. Drive pinion front bearing 9. Drain plug
10. Collapsible spacer 11. Washer 12. Pinion height adjusting washer
13. Pinion mate thrust washer 14. Thrust block 15. Side gear
16. Side gear thrust washer 17. Side bearing adjusting shim 18. Side bearing spacer
19. Outer race 20. Inner cone 21. Side bearing
22. Lock pin 23. Pinion mate shaft 24. Pinion mate gear
25. Drive pinion 26. Ring gear 27. Hypoid gear set
28. Filler plug 29. Carrier cover bolt 30. Carrier cover
31. Carrier cover gasket 32. Differential case 33. Inner cone
34. Outer race 35. Drive pinion rear bearing 36. Side bearing cap

RFD-12
REAR FINAL DRIVE ASSEMBLY
[C200]

RFD

LDIA0020E

1. Axle case 2. Front oil seal 3. Companion flange


4. Inner cone 5. Outer race 6. Drive pinion front bearing

RFD-13
REAR FINAL DRIVE ASSEMBLY
[C200]
7. Drain plug 8. Collapsible spacer 9. Washer
10. Pinion height adjusting washer 11. Pinion mate thrust washer 12. Pinion mate gear
13. Pinion mate thrust washer 14. Side gear 15. Side bearing adjusting shim
16. Outer race 17. Inner cone 18. Side bearing
19. Differential case A 20. Side gear thrust washer 21. Pinion mate shaft
22. Drive pinion 23. Ring gear 24. Hypoid gear set
25. Filler plug 26. Carrier cover bolt 27. Carrier cover
28. Carrier cover gasket 29. Side bearing spacer 30. Differential case B
31. Inner cone 32. Outer race 33. Drive pinion rear bearing
34. Side bearing cap

Pre-Inspection EDS0012V

Before disassembling final drive, perform the following inspections.


TOTAL PRELOAD
1. Turn drive pinion in both directions several times to set bearing rollers.
2. Check total preload with Tool number ST3127S000 (J25765-A).
Total preload : 1.4 - 2.9 N·m (15 - 29 kg-cm,
13 - 25 in-lb)

PD245

RING GEAR-TO-DRIVE PINION BACKLASH


Check backlash of ring gear with a dial indicator at several points.
Ring gear-to-drive pinion backlash
Gear ratio 4.636 : 0.10 - 0.15 mm (0.0041 - 0.0059 in)
Gear ratio 3.900, : 0.13 - 0.18 mm (0.0051 - 0.0071 in)
4.625

SPD196

RING GEAR RUNOUT


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

SPD702

TOOTH CONTACT
Check tooth contact. Refer to RFD-29, "TOOTH CONTACT" .

RFD-14
REAR FINAL DRIVE ASSEMBLY
[C200]
SIDE GEAR-TO-PINION MATE GEAR BACKLASH
Measure clearance between side gear thrust washer and differential A
case with a feeler gauge.
Clearance between : 0.10 - 0.20 mm (0.0039 -
side gear thrust washer 0.0079 in) B
and differential case

SPD198
RFD

Disassembly and Assembly EDS0012W

REMOVAL OF DIFFERENTIAL CASE E


1. Remove rear cover and rear cover gasket.
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 reas-
F
sembly.
● Bearing caps are line-bored during manufacture and
should be put back in their original places.
G

H
SPD714

3. Remove side bearing caps. I

SPD202 L

4. Remove differential case assembly with pry bar.


M

SPD193

RFD-15
REAR FINAL DRIVE ASSEMBLY
[C200]
NOTE:
Keep the side bearing outer races together with their respective
inner cones — do not mix them up.

SPD745

REMOVAL OF DRIVE PINION ASSEMBLY


1. Remove pinion nut while holding the companion flange using
Tool.
Tool number : KV38108300 (J44195)

APD032

2. Remove companion flange with puller.


3. Remove ABS sensor and sensor rotor.

SPD014

4. Remove drive pinion with soft hammer.


5. Remove front oil seal and pinion front bearing inner cone.

SPD206

RFD-16
REAR FINAL DRIVE ASSEMBLY
[C200]
6. Remove pinion bearing outer races with a brass drift.
A

PD349

RFD
7. Remove pinion rear bearing inner cone and pinion height adjust-
ing washer.
Tool number : ST30031000 (J22912-01) E

G
PD179

DISASSEMBLY OF DIFFERENTIAL CASE (WITHOUT LSD)


1. Remove side gears, pinion mate gears and thrust washers into differential case H
2. Remove side bearing inner cones using Tool.
● To prevent damage to bearing, engage puller jaws in
grooves. I

Tool number A : ST33051001 (J22888-20)


Tool number B : ST33061000 (J8107-2) J

SPD529

RFD-17
REAR FINAL DRIVE ASSEMBLY
[C200]
NOTE:
Be careful not to confuse the right-hand and left-hand parts.

SPD022

3. Loosen ring gear bolts in a crisscross fashion.


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

SPD024

5. Punch off pinion mate shaft lock pin from differential case.
● Lock pin is caulked at pinhole mouth on differential case.

SPD025

6. Disassemble the LH and RH differential case (4WD models).

SPD643

RFD-18
REAR FINAL DRIVE ASSEMBLY
[C200]
DISASSEMBLY OF DIFFERENTIAL CASE (WITH LSD)
Checking Differential Torque A
● Measure differential torque with Tool.
Differential torque : 40 - 58 N·m (4 - 6 kg-m, 29 - 43 B
ft-lb)
Tool number A : KV38105110 ( — )
Tool number B : KV38105120 ( — ) C
● If it is not within the specifications, inspect components of limited
slip differential.
RFD
SPD415

Disassembly E

M
WDIA0014E

1. Pinion mate shaft 2. Thrust block 3. Differential case couple bolt


4. Differential case B 5. Pinion mate thrust washer 6. Pinion mate gear
7. Side gear 8. Friction plate 9. Spring plate
10. Differential case A 11. Friction plate guide 12. Spacer
13. Friction disc 14. Friction plate

RFD-19
REAR FINAL DRIVE ASSEMBLY
[C200]
1. Remove side bearing inner cones.
● To prevent damage to bearing, engage puller jaws in
groove.
Tool number A : ST33051001 (J22888–20)
Tool number B : ST33061000 (J8107–2)

SPD529

2. Loosen ring gear bolts in a crisscross pattern.

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


● Tap evenly all around to keep ring gear from binding.

SPD552A

4. Remove couple bolts on differential cases A and B with a press.


Tool number : ST33081000 ( — )
5. Separate differential case A and B.
6. Remove component parts (discs and plates, etc.).
● Put matchmarks on gears and pressure rings so that they
can be reinstalled in their original positions from which
they are removed.

SPD276

INSPECTION
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).

RFD-20
REAR FINAL DRIVE ASSEMBLY
[C200]
Differential Case Assembly (Non LSD)
Check mating surfaces of differential case, side gears, pinion mate A
gears, pinion mate shaft, thrust block and thrust washers.

SPD584
RFD

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

SPD715
H
Contact Surfaces (With LSD)
1. Clean the disassembled parts in suitable solvent and blow dry
with compressed air. I
2. If following surfaces are found with burrs or scratches, smooth
with oil stone.
1 Differential case B J
2 Differential case A
3 Side gear
4 Pinion mate gear
5 Pinion mate shaft K
6 Thrust block (2WD and 4WD without ABS only)
7 Friction plate guide
L

SPD291

Disc and Plate (With LSD)


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

RFD-21
REAR FINAL DRIVE ASSEMBLY
[C200]
3. Check friction discs or plates for warpage.
Allowable warpage : 0.08 mm (0.0031 in)
● If it exceeds limits, replace with a new plate or disc to elimi-
nate possibility of clutch slippage or sticking.

SPD279

4. Measure frictional surfaces and projected portions of friction


disc, friction plate, spring plate, and determine each part's differ-
ences to see if the specified wear limit has been exceeded.
● Measuring points:

– A: Projected portion

– B: Frictional surface

Wear limit
A − B = Wear limit mm (in) : 0.1 mm (0.004 in) or less
● If any part has worn beyond the wear limit, and is deformed or
fatigued, replace it with a new one that is the same thickness
as the projected portion.

SPD551A

ADJUSTMENT OF DIFFERENTIAL CASE (WITH LSD)


1. End play of friction disc and friction plate can be calculated by
using following equation and should be adjusted within following
range.
● Adjustment can be made by selecting friction disc having two
different thicknesses.
E = A − (B + C)
End play E : 0.05 - 0.15 mm (0.0020 - 0.0059 in)
A: Length of differential case contact surface to differential case
inner bottom.
B: Total thickness of friction discs, friction plates, spring disc and SPD545A

spring plate in differential case on one side.


C: Length of differential case contact surface to back side of side gear.

RFD-22
REAR FINAL DRIVE ASSEMBLY
[C200]
2. Measure values of the length of the differential case contact sur-
face to the differential case inner bottom. A
Standard length A : 49.50 - 49.55 mm
(1.9488 - 1.9508 in)
B

SPD417

RFD
3. Measure thickness of each disc and plate. Number of discs and
plates (One side), Friction disc 5, Friction plate 6 and Spring
plate 2.
E
Total thickness “B” : 18.57 - 20.43 mm (0.7311
- 0.8043 in)

No. of discs and plates (One side) F


Friction discs :2
Friction plates :5
G
Spring plate :2 SPD420

Spacer :1
H
4. Measure the length of differential case contact surface to back
side of side gear.
a. Attach a dial indicator to the base plate.
I
b. Place differential case B on rear of the base plate, and install a
master gauge on case B.
Then adjust the dial indicator scale to zero with its tip on
the master gauge. J

K
SPD418

c. Install pinion mate gears, side gears and pinion mate shaft in dif-
ferential case B. L
d. Set dial indicator tip on the side gear, and read the indication.
Example:
E = A − D = A − (B + C) = 0.05 to 0.15 mm M
A = 49.52 mm
B = 19.45 mm
C = 29.7 mm
D=B+C
49.15 (D) = 19.45 (B) + 29.7 (C)
E=A−D SPD419
0.37 (E) = 49.52 (A) − 49.15 (D)
From the above equation, end play of 0.37 mm exceeds the specified range of 0.05 to 0.15 mm.
Select suitable discs and plates to adjust correctly.
SIDE BEARING PRELOAD
A selection of side bearing adjusting shims is required for successful completion of this procedure.

RFD-23
REAR FINAL DRIVE ASSEMBLY
[C200]
1. Make sure all parts are clean. Also make sure the bearings are
well lubricated with light oil or “DEXRONTM ” automatic trans-
mission fluid.
2. Place the differential carrier, with side bearings and bearing
races installed, into the final drive housing.

SPD919

3. Put the side bearing adjusting shim in place.


CAUTION:
Side bearing adjusting shim is placed on either the right or
left depending upon final drive gear ratio. Be sure to place it
on the correct side.

SPD894

4. Use Tool to place original carrier side bearing adjusting shims on


the carrier end, opposite the ring gear.
Tool number : KV38100600 (J25267)

SPD986

5. Install the side bearing caps in their correct locations using the
matchmarks made during removal, and tighten the bearing cap
bolts to specification.
Bearing cap : 88 - 98 N·m (9.0 - 10.0 kg-m,
bolts 65 - 72 ft-lb)
6. Turn the carrier several times to seat the bearings.

SPD526

7. Measure the turning resistance of the differential carrier assem-


bly at the ring gear retaining bolts with Tool.
Tool number : J8129
Differential carrier assem- : 34.3 - 39.2 N (3.5 - 4.0 kg,
bly turning resistance 7.7 - 8.8 lb)

WDIA0013E

RFD-24
REAR FINAL DRIVE ASSEMBLY
[C200]
8. If the turning resistance is not within the specification, correct as
follows: A
● If the turning resistance is less than the specified range, install
thicker side bearing adjusting shims.
● If the turning resistance is greater than the specification, B
install thinner side bearing adjusting shims.

Side bearing adjust- Refer to RFD-39, "SIDE


C
ment BEARING ADJUSTMENT" .
9. Record the total amount of shim thickness required for the cor- SPD772
rect carrier side bearing preload. RFD
10. Remove the carrier from the final drive housing. Save the
selected adjusting shims for later use during the assembly of the
final drive unit. E

G
PD344

PINION GEAR HEIGHT H


1. Make sure all parts are clean and that the bearings are well
lubricated.
I

K
SPD769

2. Assemble the pinion gear bearings into the pinion preload shim selector Tool, J34309. L
● Front pinion bearing — make sure the J34309-3 front pinion
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. M
● Rear pinion bearing — the rear pinion bearing pilot, J34309-
8, is used to center the rear pinion bearing only. The rear pin-
ion bearing locking seat, J34309-4, is used to lock the bearing
to the assembly.

SPD197A

RFD-25
REAR FINAL DRIVE ASSEMBLY
[C200]
3. Install the pinion rear bearing inner cone into the final drive
housing. Then place the pinion preload shim selector Tool,
J34309-1, on gauge screw assembly.

SPD893

4. Assemble the front pinion bearing inner cone and the J34309-2
gauge anvil. Assemble them 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. Tighten the
two sections together by hand.

SPD199A

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 Tool.
Tool number : ST3127S000 (J25765-A)
Drive pinion preload : 1.0 - 1.3 N·m (10 - 13 kg-cm,
without front oil seal 8.7 - 11.3 in-lb)

SPD234A

7. Place the J34309-11 pinion height adapter onto the gauge plate
and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

SPD208A

RFD-26
REAR FINAL DRIVE ASSEMBLY
[C200]
Pinion Height Adjusting Washer Selection
1. Now, position the side bearing discs, J25269-4, and arbor firmly A
into the side bearing bores.

SPD211A
RFD

2. Install the side bearing caps and tighten the side bearing cap bolts to proper torque.
Side bearing cap bolts : 93 - 103 N·m (9.5 - 10.5 kg-m, E
69 - 76 ft-lb)
3. Select the correct standard pinion height adjusting washer thick-
F
ness. Select by using a standard gauge of 3 mm (0.12 in) and
J34309-101 feeler gauge. Measure the distance between the
J34309-11 pinion height adapter including the standard gauge
and the arbor. G
4. Write down the exact measurement (the value of feeler gauge).

SPD204A
I
5. Correct the pinion height adjusting washer size by referring to
the “pinion head number”.
● There are two numbers painted on the pinion gear. The
J
first one refers to the pinion and ring gear as a matched
set. This number should be the same as the number on
the ring gear. The second number is the “pinion head K
height number”. It refers to the ideal pinion height from
standard for quietest operation.
● Use the following chart to determine the correct pinion L
height adjusting washer:
SPD542
Add or remove from the standard
Pinion head height number pinion height adjusting washer thick- M
ness 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)

RFD-27
REAR FINAL DRIVE ASSEMBLY
[C200]
Add or remove from the standard
Pinion head height number pinion height adjusting washer thick-
ness measurement
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)

6. Select the correct pinion height adjusting washer.


Pinion height adjust- : RFD-39, "DRIVE PINION
ing washer HEIGHT ADJUSTMENT" .
7. Remove the J34309 pinion preload shim selector Tool from the
final drive housing. Then disassemble to retrieve the pinion
bearings.

SPD205A

RFD-28
REAR FINAL DRIVE ASSEMBLY
[C200]
TOOTH CONTACT
Checking gear tooth contact pattern is necessary to verify correct relationship between ring gear and drive pin- A
ion.
Hypoid gear set which is not positioned properly may be noisy, or have short life or both. With the checking or
gear tooth contact pattern, the most desirable contact for low noise level and long life can be assured. B
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. C

RFD

E
SPD199

3. Hold companion flange steady and rotate the ring gear in both F
directions.

SPD200
I

SPD007-B

RFD-29
REAR FINAL DRIVE ASSEMBLY
[C200]
ASSEMBLY OF DIFFERENTIAL CASE (WITHOUT LSD)
1. Measure clearance between side gear thrust washer and differ-
ential case (4WD models).
Clearance between side : 0.10 - 0.20 mm (0.0039 -
gear thrust washer and 0.0079 in)
differential case (A – B)
The clearance can be adjusted with side gear thrust washer.
Refer to RFD-38, "SIDE GEAR ADJUSTMENT (WITHOUT
LSD)" .
2. Install side gears, pinion mate gears and thrust washers into dif-
ferential case
3. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see that they turn properly.

SPD656

4. Install differential case LH and RH (4WD models).

SPD643

5. Place differential case on ring gear.


6. Apply Genuine Medium Strength Locking Sealant or equivalent
to ring gear bolts, and install them.
● Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .
● Tighten bolts in a crisscross pattern.

Tool number KV10112100 (BT8653-A)


Ring gear bolts
Step 1 : 53.9 - 63.7 N·m (5.5 - 6.4 kg-m, SPD746
40 - 46 ft-lb)
Step 2 : 34° - 39° degrees rotation

RFD-30
REAR FINAL DRIVE ASSEMBLY
[C200]
7. Press-fit side bearing inner cones on differential case with Tool.
A
Tool number A : ST33230000 (J25805-01)
Tool number B : ST33061000 (J8107-2)
B

PD353

RFD
ASSEMBLY OF DIFFERENTIAL CASE (WITH LSD)
● Prior to assembling discs and plates, properly lubricate them by dipping them in limited slip differential oil.
Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .
E
1. Alternately position specified number of friction plates and fric-
tion discs on rear of side gear.
● Always position a friction plate first on rear of side gear.
F
Friction discs :2
Fiction plates :5
Spacer :1 G

SPD546A

L
2. Install two spring plates.

SPD547A

RFD-31
REAR FINAL DRIVE ASSEMBLY
[C200]
3. Install friction plate guides.
● Correctly align the raised portions of friction plates, and
apply LSD gear oil to inner surfaces of friction plate
guides to prevent them from falling.

SPD424

4. Install differential case B over side gear, discs, plates and fric-
tion 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.

SPD425

5. Install pinion mate gears and pinion mate thrust washers on pin-
ion mate shaft, then install pinion mate shaft in differential case
B.
6. Install side gear to pinion mate gears.

SPD426

7. Install thrust block.


● Equipped on 2WD vehicle and 4WD without ABS only.

SPD427

RFD-32
REAR FINAL DRIVE ASSEMBLY
[C200]
8. Install each disc and plate.
● Use same procedures as outlined in steps 1 through 4. A

SPD429

RFD
9. Install differential case A.
● Position differential cases A and B by correctly aligning
the matchmarks stamped on cases. E

G
SPD430

10. Tighten differential case couple bolts.


H
Differential case couple : 64 - 74 N·m (6.5 - 7.5 kg-m,
bolts 47 - 54 ft-lb)
11. Place ring gear on differential case and tighten ring gear bolts. I
● Tighten bolts in a crisscross pattern.

Tool number KV10112100 (BT8653-A) J


Ring gear bolts
Step 1 : 53.9 - 63.7 N·m (5.5 - 6.4 kg-m, SPD364A
K
40 - 46 ft-lb)
Step 2 : 34° - 39° degrees rotation
12. Install side bearing inner race. L
13. Check differential torque. Refer to RFD-19, "Checking Differential Torque" .

RFD-33
REAR FINAL DRIVE ASSEMBLY
[C200]
INSTALLATION OF DRIVE PINION ASSEMBLY
1. Press-fit front and rear bearing outer races with Tools.
Tool number A : ST30611000 (J25742-1)
Tool number B : ST30621000 (J25742-5)
Tool number C : ST30613000 (J25742-3)

SPD679

2. Select pinion height adjusting washer. Refer to RFD-25, "PIN-


ION GEAR HEIGHT" .
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 (J26010-01)

SPD377

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 : KV38100500 (J25273)

SPD557

RFD-34
REAR FINAL DRIVE ASSEMBLY
[C200]
6. Place drive pinion bearing spacer, drive pinion bearing adjusting
washer and drive pinion in gear carrier. A

SPD222
RFD
7. Install ABS sensor unit and sensor rotor.
ABS sensor unit bolt : 18 - 24 N·m (1.8 - 2.4 kg-m,
E
13 - 17 ft-lb)
8. Insert companion flange onto drive pinion by tapping the com-
panion flange with a soft hammer until fully seated. F

G
SPD708

9. Hold companion flange using Tool and tighten the pinion nut. H
The threaded portion of drive pinion and pinion nut should
be free from oil or grease.
Tool number : KV38108300 (J44195) I
Pinion nut : 127 - 294 N·m (13 - 30 kg-m,
94 - 217 ft-lb)
J

APD032 K
10. Tighten the pinion nut by very small degrees until the specified
preload is achieved. When checking the preload, turn the drive
pinion in both directions several times to set the bearing rollers. L
Tool number : ST3127S000 (J25765-A)
Pinion bearing preload : 1.1 - 1.4 N·m (12 - 14 kg-cm,
M
10 - 12 in-lb)

SPD241

RFD-35
REAR FINAL DRIVE ASSEMBLY
[C200]
INSTALLATION OF DIFFERENTIAL CASE
This procedure will have to be repeated if:
● Maximum preload is achieved before the minimum pinion
nut torque is reached.
● Minimum preload is not achieved before maximum pinion
nut torque is reached.
1. Select side bearing adjusting shim. Refer to RFD-23, "SIDE
BEARING PRELOAD" .
2. Install differential case assembly with side bearing outer races
into gear carrier.
SPD203

3. Insert left and right side bearing adjusting shims in place


between side bearing outer races and differential carrier asse-
bly.

SPD558

4. Drive in side bearing spacer with Tool.


Tool number : KV38100600 (J25267)

SPD709

5. Align matchmark on bearing cap with that on differential gear


carrier and install side bearing cap on gear carrier with soft ham-
mer.
Side bearing cap bolts : 93 - 103 N·m (9.5 - 10.5
kg-m, 69 - 76 ft-lb)

SPD226

RFD-36
REAR FINAL DRIVE ASSEMBLY
[C200]
6. Measure ring gear-to-drive pinion backlash with a dial indicator.
Ring gear-to-drive pin- A
ion backlash
Gear ratio 3.900, 4.625 : 0.13 - 0.18 mm (0.0051 -
0.0071 in) B

Gear ratio 4.636 : 0.10 - 0.15 mm (0.0041 -


0.0059 in)
C
● If backlash is too small, decrease thickness of right shim and
increase thickness of left shim by the same amount.
SPD196
● If backlash is too great, reverse the above procedure. RFD
● Never change the total amount of shims as it will change the bearing preload.

7. Check total preload with Tool.


E
● When checking preload, turn drive pinion in both direc-
tions several times to seat bearing rollers correctly.
Total preload : 1.4 - 2.9 N·m (15 - 29 kg-cm, F
13 - 25 in-lb)
Tool number : ST3127S000 (J25765-A)
G

SPD241
H
● If preload is too great, remove the same amount of shim from
each side.
I
● 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 as it will change ring gear-to-drive pinion back- J
lash.
8. Recheck ring gear-to-drive pinion backlash because increase or
decrease in thickness of shims will cause change of ring gear- K
to-pinion backlash.
SPD561

9. Check runout of ring gear with a dial indicator. L

Ring gear : 0.08 mm (0.0031 in)


runout limit
M
●If backlash varies excessively in different places, the variance
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 differential
case should be replaced.
10. Check tooth contact. Refer to RFD-29, "TOOTH CONTACT" . SPD702

11. Install new rear cover gasket and rear cover.


12. Tighten rear cover bolts.
Rear cover bolts : 44 - 54 N·m (4.5 - 5.5 kg-m, 33 - 40 ft-lb)

RFD-37
SERVICE DATA AND SPECIFICATIONS (SDS)
[C200]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

C200 EDS0012X

GENERAL SPECIFICATIONS
2WD Models
Engine KA24DE VG33E
Vehicle grade XE XE, SE
M/T A/T Standard Optional
Rear final drive C200
2 Pinion 4 Pinion LSD
Gear ratio 3.900 4.625 4.636
Number of teeth (Ring gear drive pinion) 39/10 37/8 51/11

Oil capacity (Approx.) (US pt., Imp pt) 1.3 (2 3/4, 2 1/4)

4WD Model
Engine VG33E
Vehicle Grade XE
Transmission Standard Optional
Standard
Rear final drive
C200
4-Pinion LSD
Gear ratio 4.636
Number of teeth (Ring gear/drive pinion) 51/11

Oil capacity (Approx.) (US pt, lmp pt) 1.3 (2-3/4, 2-1/4)

RING GEAR RUNOUT


Ring gear runout limit mm (in) 0.08 (0.0031)

SIDE GEAR ADJUSTMENT (WITHOUT LSD)


Side gear backlash (Clearance between side gear thrust washer
0.10 - 0.20 (0.0039 - 0.0079)
and differential case) mm (in)
Available side gear thrust washers (2wd)
Thickness mm (in) Part number*
0.75 (0.0295) 38424-N3110
0.78 (0.0307) 38424-N3111
0.81 (0.0319) 38424-N3112
0.84 (0.0331) 38424-N3113
0.87 (0.0343) 38424-N3114
0.90 (0.0354) 38424-N3115
0.93 (0.0366) 38424-N3116
Available side gear thrust washers (4wd)
Thickness mm (in) Part number*
0.75 (0.0295) 38424-0C000
0.78 (0.0307) 38424-0C001
0.81 (0.0319) 38424-0C002
0.84 (0.0331) 38424-0C003
0.87 (0.0343) 38424-0C004
0.90 (0.0354) 38424-0C005
0.93 (0.0366) 38424-0C006

*Always check with the Parts Department for the latest parts information.

RFD-38
SERVICE DATA AND SPECIFICATIONS (SDS)
[C200]
SIDE BEARING ADJUSTMENT
Differential carrier assembly turning resistance N (kg, lb) 34.3 - 39.2 (3.5 - 4.0, 7.7 - 8.8)
A

Thickness mm (in) Part number*


2.00 (0.0787) 38453-N3100 B
2.05 (0.0807) 38453-N3101
2.10 (0.0827) 38453-N3102
2.15 (0.0846) 38453-N3103
Available 2.20 (0.0866) 38453-N3104 C
side bear- 2.25 (0.0886) 38453-N3105
ing adjust- 2.30 (0.0906) 38453-N3106
ing shims 2.35 (0.0925) 38453-N3107
2.40 (0.0945) 38453-N3108 RFD
2.45 (0.0965) 38453-N3109
2.50 (0.0984) 38453-N3110
2.55 (0.1004) 38453-N3111
2.60 (0.1024) 38453-N3112 E
*Always check with the Parts Department for the latest parts information.

TOTAL PRELOAD ADJUSTMENT F


Total preload N·m (kg-cm, in-lb) 1.4 - 2.9 (15 - 29, 13 - 25)
Gear ratio 3.900, 4.625 0.13 - 0.18 (0.0051 - 0.0071)
Ring gear-to-drive pinion backlash mm (in) G
Gear ratio 4.636 0.10 - 0.15 (0.0041 - 0.0059)

DRIVE PINION HEIGHT ADJUSTMENT


Thickness mm (in) Part number* H
3.09 (0.1217) 38154-P6017
3.12 (0.1228) 38154-P6018
3.15 (0.1240) 38154-P6019 I
3.18 (0.1252) 38154-P6020
3.21 (0.1264) 38154-P6021
3.24 (0.1276) 38154-P6022
3.27 (0.1287) 38154-P6023 J
Available 3.30 (0.1299) 38154-P6024
drive pinion 3.33 (0.1311) 38154-P6025
height 3.36 (0.1323) 38154-P6026
adjusting 3.39 (0.1335) 38154-P6027 K
washers 3.42 (0.1346) 38154-P6028
3.45 (0.1358) 38154-P6029
3.48 (0.1370) 38154-P6030
L
3.51 (0.1382) 38154-P6031
3.54 (0.1394) 38154-P6032
3.57 (0.1406) 38154-P6033
3.60 (0.1417) 38154-P6034 M
3.63 (0.1429) 38154-P6035
3.66 (0.1441) 38154-P6036
*Always check with the Parts Department for the latest parts information.

DRIVE PINION PRELOAD ADJUSTMENT


Drive pinion bearing preload adjusting method Collapsible spacer
Drive pinion preload with front oil seal N·m (kg-cm, in-lb) 1.1 - 1.4 (12 - 14, 10 - 12)
Drive pinion preload without front oil seal N·m (kg-cm, in-lb) 1.0 - 1.3 (11 - 13, 9 - 11)

DIFFERENTIAL TORQUE ADJUSTMENT (WITH LSD)


Differential torque N·m (kg-m, ft-lb) 40 - 58 (4.0 - 6.0, 29 - 43)
Number of discs and plates
Friction disc 2
Friction plate 5
Spring plate 2
Spacer 1

RFD-39
SERVICE DATA AND SPECIFICATIONS (SDS)
[C200]
Wear limit of plate and disc mm
0.1 (0.004)
(in)
Allowable warpage of friction disc
0.08 (0.0031)
and plate mm (in)
Total thickness mm (in)) 18.57 - 20.43 (0.7311 - 0.8043)
Part name Thickness mm (in)) Part number*
38433-C6004
1.4 (0.055)
(adjusting type)
Friction disc
38433-C6002
1.5 (0.059)
(standard type)
38433-C6003
1.6 (0.063)
Available discs and plates (one side) (adjusting type)
1.4 (0.055) 38432-C6002
Friction plate 1.5 (0.059) 38432-C6001
1.6 (0.063) 38432-C6003
Spring plate 1.5 (0.059) 38435-S9200
Spacer 6.0 (0.236) 38454-S9200
*Always check with the Parts Department for the latest parts information.

RFD-40
PREPARATION
[H233B]
PREPARATION PFP:00002
A
Special Service Tools EDS0012Y

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
B
(Kent-Moore No.) Description
Tool name
ST3127S000 Measuring pinion bearing preload and total
(J25765-A) preload C
Preload gauge
1 GG91030000
(J25765)
Torque wrench
RFD
2 HT62940000
( — )
Socket adapter E
3 HT62900000 NT124

( — )
Socket adapter
ST06340000 Mounting final drive F
(J24310, J34310)
Differential attachment
G

NT140
H
ST32580000 Adjusting side bearing preload and backlash
(J34312) (ring gear-drive pinion)
Differential side bearing adjusting nut
wrench I

J
NT141

KV38108300 Removing and installing propeller shaft lock


(J-44195) nut, and drive pinion lock nut
Companion flange wrench K

L
NT771

ST3090S000 Removing and installing drive pinion rear in-


( — ) ner cone M
Drive pinion rear inner race puller set a: 79 mm (3.11 in) dia.
1 ST30031000 b: 45 mm (1.77 in) dia.
(J22912-01) c: 35 mm (1.38 in) dia.
Puller
2 ST30901000
(J26010-01)
NT527
Base
ST3306S001 Removing and installing differential side bear-
Differential side bearing puller set ing inner cone
1 ST33051001 a: 28.5 mm (1.122 in) dia.
(J22888-20) b: 38 mm (1.50 in) dia.
Body
2 ST33061000
(J8107-2)
Adapter NT072

RFD-41
PREPARATION
[H233B]
Tool number
(Kent-Moore No.) Description
Tool name
ST33190000 Installing side bearing inner cone
(J25523) a: 52 mm (2.05 in) dia.
Differential side bearing drift b: 45.5 mm (1.791 in) dia.
c: 34 mm (1.34 in) dia.

NT085

ST33081000 Installing side bearing inner cone and remov-


( — ) ind and installing differential case couple bolts
Side bearing puller adapter a: 43 mm (1.69 in) dia.
b: 33.5 mm (1.319 in) dia.

NT431

ST30611000 Installing pinion rear bearing outer race


(J25742-1) (Use with ST30621000 or ST30613000)
Drift

NT090

ST30621000 Installing pinion rear bearing outer race


(J25742-5) a: 79 mm (3.11 in) dia.
Drift b: 59 mm (2.32 in) dia.

NT073

ST30613000 Installing pinion front bearing outer race


(J25742-3) (Use with ST30611000)
Drift a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.

NT073

KV381025S0 Installing front oil seal


( — ) a: 77 mm (3.03 in) dia.
Oil seal fitting tool b: 55 mm (2.17 in) dia.
1 ST30720000 c: 71 mm (2.80 in) dia.
(J25405) d: 65 mm (2.56 in) dia.
Drift bar
2 KV38102510
( — )
NT525
Drift
(J34309) Adjusting bearing pre-load and gear height
Differential shim selector

NT134

RFD-42
PREPARATION
[H233B]
Tool number
(Kent-Moore No.) Description A
Tool name
(J25269-18) Selecting pinion height adjusting washer
Side bearing discs B
(2 Req'd)

NT135

KV381052S0 Checking differential torque on limited slip dif- RFD


( — ) ferential
Rear axle shaft dummy
1 KV38105210
( — ) E
Torque wrench side
2 KV38105220
( — )
NT142
Vise side F
KV38100500 Installing front oil seal
(J25273) a: 85 mm (3.35 in) dia.
Gear carrier front oil seal drift b: 60 mm (2.36 in) dia. G

H
NT115

RFD-43
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
[H233B]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003

NVH Troubleshooting Chart EDS0012Z

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

FAX-4,RAX-5 , FSU-4 , RSU-4


RFD-56,RFD-57

RFD-56

RFD-56

RFD-49

MA-12

RAX-5
WT-3
PR-3

BR-6

PS-5
--—
Reference page

Companion flange excessive runout

AXLE AND SUSPENSION


Improper gear contact

PROPELLER SHAFT
Tooth surface worn
Possible cause and SUSPECTED PARTS

Incorrect backlash
Rough gear tooth

Improper gear oil

ROAD WHEEL

DRIVESHAFT

STEERING
BRAKES
TIRES
Symptom DIFFERENTIAL Noise × × × × × × × × × × × × ×
×: Applicable

RFD-44
FRONT OIL SEAL
[H233B]
FRONT OIL SEAL PFP:38189
A
Removal and Installation EDS00130

1. Remove propeller shaft. Refer to PR-8, "Removal and Installation" .


2. Hold companion flange using Tool and loosen drive pinion nut. B
Tool number : KV38108300 (J-44195)

RFD

SPD479A E
3. Remove companion flange.
4. Remove ABS sensor and sensor rotor (2WD models).
F

SPD737

5. Remove front oil seal. I

L
SPD738

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


Press front oil seal into carrier using Tool. M
Tool number : KV38100500 (J25273)
7. Install ABS sensor and sensor rotor (2WD models).
NOTE:
Always install a new sensor rotor.
ABS sensor bolt : 8 - 11 N·m (0.8 - 1.1 kg-m,
5.8 - 8.0 ft-lb)
8. Install companion flange and drive pinion nut. SPD739

RFD-45
FRONT OIL SEAL
[H233B]
9. Hold companion flange using Tool and tighten drive pinion nut.
Tool number : KV38108300 (J-44195)

Drive pinion nut : 127 - 294 N·m (13.0 - 30.0 kg-m,


94 - 217 lb-ft)

SPD479A

10. Install rear propeller shaft. Refer to PR-8, "Removal and Installation" .

RFD-46
REAR FINAL DRIVE ASSEMBLY
[H233B]
REAR FINAL DRIVE ASSEMBLY PFP:38300
A
Removal and Installation EDS00131

REMOVAL
CAUTION: B
Be careful not to damage spline, sleeve yoke and front oil seal when removing propeller shaft.
Before removing the final drive assembly or rear axle assembly, disconnect the ABS sensor harness
connector from the assembly and move it 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 inoperative. C
1. Remove rear propeller shaft. Refer to PR-8, "Removal and Installation" .
● Plug front end of transfer.
RFD
2. Remove axle shaft. Refer to RAX-8, "Removal" .
3. Remove rear final drive nuts.
INSTALLATION E
Installation is in the reverse order of removal.
Rear final drive mounting nuts : Refer to RFD-48, "Components" .
F
● Fill final drive with recommended gear oil. Refer to MA-12,
"RECOMMENDED FLUIDS AND LUBRICANTS" .

I
SPD123

● Pay attention to the direction of gasket.


J

SPD767
M

RFD-47
REAR FINAL DRIVE ASSEMBLY
[H233B]
Components EDS00132

H233B

WDIA0067E

RFD-48
REAR FINAL DRIVE ASSEMBLY
[H233B]
1. Pinion mate shaft 2. Pinion mate gear 3. Pinion mate thrust washer
4. Differential case 5. Ring gear bolt 6. Side bearing adjuster
A
7. Side bearing cap bolt 8. Side bearing cap 9. Outer race
10. Inner cone 11. Side bearing 12. Ring gear
B
13. Drive pinion 14. Hypoid gear set 15. Drive pinion height adjusting washer
16. Drive pinion bearing adjusting spacer 17. Drive pinion bearing adjusting shim 18. Rear final drive mounting stud
19. Rear final drive mounting nut 20. ABS sensor mounting bolt 21. Washer
C
22. Pinion nut 23. Companion flange 24. Rear wheel sensor rotor (2WD models)
25. ABS sensor unit (2WD models) 26. Front oil seal 27. Inner cone
28. Pinion front bearing 29. Outer race 30. Gear carrier
RFD
31. Gasket 32. Outer race 33. Drive pinion rear bearing
34. Inner cone 35. Lock pin 36. Side gear
37. Side gear thrust washer
E
Pre-Inspection EDS00133

Before disassembling the final drive, perform the following inspections.


F
TOTAL PRELOAD
1. Turn the drive pinion in both directions several times to seat bearing rollers correctly.
2. Check total preload with Tool. G
Tool number : ST3127S000 (J-25765-A)
Total preload : 1.7 - 2.5 N·m (17 - 25 kg-cm,
15 - 22 in-lb) H

SPD149 J

RING GEAR TO DRIVE PINION BACKLASH


● Check backlash of ring gear with a dial indicator at several K
points.
Ring gear-to-drive pinion backlash : 0.13 - 0.18 mm
(0.0051 - 0.0071 in) L

SPD246

RING GEAR RUNOUT


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

SPD247

RFD-49
REAR FINAL DRIVE ASSEMBLY
[H233B]
TOOTH CONTACT
● Check tooth contact. Refer to RFD-63, "TOOTH CONTACT" .
SIDE GEAR TO PINION MATE GEAR BACKLASH
● Measure clearance between side gear thrust washer and differ-
ential case with a feeler gauge.
Clearance between side gear : 0.10 - 0.20 mm
thrust washer and differential case (0.0039 - 0.0079 in)

SPD004

Disassembly and Assembly EDS00134

REMOVAL OF DIFFERENTIAL CASE ASSEMBLY


1. Mount final drive assembly on Tool.
Tool number : ST06340000 (J-24310, J-34310)

SPD683

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 reas-
sembly.

SPD249

3. Remove side lock fingers and side bearing caps.


● Bearing caps are line-bored during manufacture and should
be put back in their original places.

SPD250

RFD-50
REAR FINAL DRIVE ASSEMBLY
[H233B]
4. Remove side bearing adjuster using Tool.
Tool number : ST32580000 (J-34312) A

SPD684

RFD
5. Remove differential case assembly with a pry bar.
● Keep the side bearing outer races together with their respec-
tive inner cones — do not mix them up.
E

G
SPD685

SPD011

REMOVAL OF DRIVE PINION ASSEMBLY


1. Hold companion flange using Tool and remove drive pinion nut.
L
Tool number : KV38108300 (J-44195)
2. Remove companion flange with puller.
M
3. Remove ABS sensor unit and sensor rotor (2WD models).

SPD480A

RFD-51
REAR FINAL DRIVE ASSEMBLY
[H233B]
4. Take out drive pinion together with pinion rear bearing inner
cone, drive pinion bearing spacer and pinion bearing adjusting
shim.

SPD687

5. Remove front oil seal and pinion front bearing inner cone.
6. Remove pinion bearing outer races with a brass drift.

SPD563

7. Remove pinion rear bearing inner cone and drive pinion adjust-
ing washer.
Tool number : ST30031000 (J-22912-01)

SPD542A

RFD-52
REAR FINAL DRIVE ASSEMBLY
[H233B]
DISASSEMBLY OF DIFFERENTIAL CASE (NON LSD)
1. Remove lock pin and remove the side gears, pinion mate gears and pinion mate shaft. A
2. Remove side bearing inner cones.
Tool number A: ST33051001 (J-22888-20)
B
Tool number B: ST33061000 (J-8107-2)
To prevent damage to bearing, engage puller jaws in groove.
C

RFD

SPD529 H
● Be careful not to confuse the left-hand and right-hand parts.
● Keep bearing and bearing race for each side together.
I

SPD022

L
3. Loosen ring gear bolts in a crisscross pattern.

4. Tap ring gear off differential case with a soft hammer. M


● Tap evenly all around to keep ring gear from binding.

SPD024

RFD-53
REAR FINAL DRIVE ASSEMBLY
[H233B]
5. Drive out pinion mate shaft lock pin, with punch from ring gear
side.
● Lock pin is caulked at pinhole mouth on differential case.

SPD025

DISASSEMBLY OF DIFFERENTIAL CASE (WITH LSD)


Checking Differential Torque
CAUTION:
Do not run engine when only one wheel (rear) is off the ground.
● Measure differential torque with Tool.
Differential torque : 40 - 58 N·m (4 - 6 kg-m, 29 - 43 ft-lb)
Tool number A: KV38105210 ( — )
Tool number B: KV38105220 ( — )
● If it is not within the specifications, inspect components of limited
slip differential.

SPD415

RFD-54
REAR FINAL DRIVE ASSEMBLY
[H233B]
Disassembly
A

RFD

WDIA0017E I
1. Pinion mate shaft 2. Differential case B 3. Differential case couple bolt
4. Pinion mate thrust washer 5. Pinion mate gear 6. Side gear
J
7. Friction plate 8. Spring plate 9. Differential case A
10. Friction plate guide 11. Spacer 12. Friction disc
13. Friction plate 14.
K
1. Remove side bearing inner cones.
● To prevent damage to bearing, engage puller jaws in groove.
L
Tool number A: ST33051001 (J-22888–20)
Tool number B: ST33061000 (J-8107–2)
M

SPD529

RFD-55
REAR FINAL DRIVE ASSEMBLY
[H233B]
2. Loosen ring gear bolts in a crisscross pattern.

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


● Tap evenly all around to keep ring gear from binding.

SPD552A

4. Remove differential case couple bolts with a press.


Tool number : ST33081000 ( — )
5. Separate differential case A and B.
6. Remove component parts (discs and plates, etc.).
● Put matching marks on component parts so that they can be
reinstalled in their original positions from which they were
removed.

SPD363A

INSPECTION
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 (Non LSD)
Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft, and thrust washers.

SPD530-A

Bearing
1. Thoroughly clean bearing.
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.

SPD715

RFD-56
REAR FINAL DRIVE ASSEMBLY
[H233B]
Contact Surfaces (With LSD)
1. Clean the disassembled parts in suitable solvent and blow dry A
with compressed air.
2. If following surfaces are found with burrs or scratches, smooth
with oil stone. B
1 Differential case B
2 Differential case A
3 Side gear
C
4 Pinion mate gear
5 Pinion mate shaft
6 Friction plate guide
RFD

SPD359A

Disc and Plate (With LSD) H


1. Clean the discs and plates in suitable solvent and blow dry with compressed air.
2. Inspect discs and plates for wear, nicks and burrs.
3. Check friction discs or plates for any warping. I
Maximum allowable warping : 0.08 mm (0.0031 in)
● If it exceeds limits, replace with a new plate to eliminate possi- J
bility of clutch slippage or sticking.

L
SPD279

RFD-57
REAR FINAL DRIVE ASSEMBLY
[H233B]
4. Measure frictional surfaces and projected portions of friction
disc, friction plate, spring plate, and determine each part's differ-
ences to see if the specified wear limit has been exceeded.
● Measuring points:

– A: Projected portion

– B: Frictional surface

Wear limit
A − B = Wear limit mm (in) : 0.1 mm (0.004 in) or less
● If any part has worn beyond the wear limit, and deformed or
fatigued, replace it with a new one that is the same thickness
as the projected portion.

SPD551A

ADJUSTMENT OF DIFFERENTIAL CASE (WITH LSD)


1. End play of friction disc and friction plate can be calculated by
using following equation and should be adjusted within following
range.
● Adjustment can be made by selecting friction disc or friction
plate having three different thicknesses.
E = A − (B + C)
(one side)
End play E : 0.05 - 0.15 mm (0.0020 - 0.0059 in)
A: Length of differential case contact surface to differential case
inner bottom. SPD545A

B: Total thickness of friction discs, friction plates, spring plate


and spacer in differential case on one side.
C: Length of differential case contact surface to back side of side gear.
2. Measure values of the length of differential case contact surface
to differential case inner bottom.
Standard length A : 49.50 - 49.55 mm
(1.9488 - 1.9508 in)

SPD417

RFD-58
REAR FINAL DRIVE ASSEMBLY
[H233B]
3. Measure thickness of each disc and plate. Number of discs and
plates (One side), Friction disc 5, Friction plate 6 and Spring A
plate 2.
Total thickness “B” : 18.57 - 20.43 mm (0.7311
- 0.8043 in) B

No. of discs and plates (One side)


Friction disc :2 C
Friction plates :5
Spring plates :2 SPD420

Spacer :1 RFD

4. Measure values of the length of differential case contact surface


to back side of side gear. E
a. Attach a dial indicator to the base plate.
b. Place differential case B on the base plate, and install a master
gauge on case B. F
● Then adjust the dial indicator scale to zero with its tip on
the master gauge.
G

SPD418

H
c. Install pinion mate gears, side gears and pinion mate shaft in dif-
ferential case B.
d. Set dial indicator tip on the rear of side gear, and read the indi- I
cation.
Example:
E = A − D = A − (B + C) = 0.05 to 0.15 mm
A = 49.52 mm J
B = 19.45 mm
C = 29.7 mm
D=B+C K
49.15 (D) = 19.45 (B) + 29.7 (C) SPD419
E=A−D
0.37 (E) = 49.52 (A) − 49.15 (D)
L
From the above equation, end play of 0.37 mm exceeds the specified range of 0.05 to 0.15 mm.
Select suitable discs and plates to adjust correctly.
PINION GEAR HEIGHT M
1. Make sure all parts are clean and that the bearings are well
lubricated.

SPD196A

2. Assemble the pinion gear bearings into the pinion pre-load shim selector tool, J34309.

RFD-59
REAR FINAL DRIVE ASSEMBLY
[H233B]
● Rear Pinion Bearing — the rear pinion bearing pilot, J34309-
8, is used to center the rear pinion bearing only. The rear pin-
ion bearing locking seat, J34309-4, is used to lock the bearing
to the assembly.
● 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.

SPD197A

3. Place the pinion preload shim selector tool gauge screw assem-
bly, J34309-1, with the pinion rear bearing inner cone installed,
into the final drive housing.

SPD216A

4. Install the J34309-2 gauge anvil with the front pinion bearing 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 sections by hand to set bear-
ing preload.
5. Turn the assembly several times to seat the bearings.

SPD217A

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


anvil using Tool.
Tool number : ST3127S000 (J25765-A)
Pinion bearing preload : 1.2 - 1.5 N·m (12 - 15 kg-cm,
(Without front oil seal) 10 - 13 in-lb)

SPD234A

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


gauge plate and tighten it by hand.

SPD208A

RFD-60
REAR FINAL DRIVE ASSEMBLY
[H233B]
PINION HEIGHT ADJUSTING WASHER SELECTION
CAUTION: A
Make sure all machined surfaces are clean.
8. Position the J25269-18 side bearing discs and the arbor into the
side bearing bores. B

SPD286A

RFD
9. Install the bearing caps and tighten the bearing cap bolts.
Side bearing cap bolts : Refer to RFD-48, "Compo-
nents" . E

G
SPD237A

10. Select the correct standard pinion height adjusting washer thick-
ness using a standard gauge of 2.5, 3.0, or 3.5 mm (0.098, H
0.118, or 0.138 in) and the J34309-101 feeler gauge.
Measure the distance between the J34309-12 “H233B” pinion
height adapter and the arbor. I
11. Write down the exact total measurement (the value of feeler
gauge).
J

SPD204A
K
12. Correct the drive pinion height adjusting washer size by referring
to the “pinion head height number”.
● There are two numbers painted on the drive pinion. The first L
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 sec-
ond number is the “pinion head height number”, and it refers M
to the ideal pinion height from standard for the quietest opera-
tion. Use the following chart to determine the correct drive
pinion height adjusting washer. Refer to RFD-72, "Drive Pin-
ion Height Adjustment" .
SPD542
Add or remove from the selected
Pinion head height number standard drive pinion height adjust-
ing 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)

RFD-61
REAR FINAL DRIVE ASSEMBLY
[H233B]
Add or remove from the selected
Pinion head height number standard drive pinion height adjust-
ing washer thickness measurement
+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 drive pinion height adjusting washer. Refer to RFD-72, "Drive Pinion Height Adjust-
ment" .
14. Remove the J34309 pinion preload shim selector tool from the
final drive housing and disassemble to retrieve the pinion bear-
ings.

SPD220A

RFD-62
REAR FINAL DRIVE ASSEMBLY
[H233B]
TOOTH CONTACT
Gear tooth contact pattern check is necessary to verify correct relationship between ring gear and drive pinion. A
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. B
2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.
C

RFD

SPD005 E

3. Hold companion flange steady by hand and rotate the ring gear
in both directions. F

SPD695

SPD007-B

RFD-63
REAR FINAL DRIVE ASSEMBLY
[H233B]
ASSEMBLY OF DIFFERENTIAL CASE (NON LSD)
1. Install side gears, pinion mate gears and thrust washers into dif-
ferential case.
The clearance can be adjusted with side gear thrust washer.
Refer to RFD-71, "Side Gear Adjustment" .

SPD552

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.
Backlash between side gear and : 0.10 – 0.20 mm
pinion mate gear (Clearance (0.0039 – 0.0079 in)
between side gear thrust washer
and differential case)
4. Install a new pinion mate shaft lock pin with a punch.
SPD258
NOTE:
● Always use a new lock pin.

● Make sure lock pin is flush with case.

SPD030

5. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see that they turn properly.

SPD322

6. Install ring gear on differential case and tighten ring gear bolts.
● Tighten bolts in a crisscross pattern.
Tool number KV10112100 (BT-8653-A)
Ring gear bolts
Step 1 : 53.9 - 63.7 N·m (5.5 - 6.4 kg-m,
40 - 46 lb-ft)
Step 2 : 34° - 39° degrees rotation

RFD-64
REAR FINAL DRIVE ASSEMBLY
[H233B]
7. Press-fit side bearing inner races on differential case with Tool.
A
Tool number A: ST33190000 (J-25523)
Tool number B: ST33081000 ( — )
B

PD244

RFD
ASSEMBLY OF DIFFERENTIAL CASE (WITH LSD)
● Prior to assembling discs and plates, properly lubricate them by dipping them in limited slip differential oil.
Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .
E
1. Position specified number of friction plates, friction discs and
spacer on rear of side gear.
● Always position a friction plate first on rear of side gear.
F
No. of discs and plates (One side)
Friction disc :2
Friction plates :5 G
Spacer :1
H

SPD546A

L
2. Install two spring plates.

SPD547A

RFD-65
REAR FINAL DRIVE ASSEMBLY
[H233B]
3. Install friction plate guides.
● Correctly align the raised portions of friction plates, and
apply LSD gear oil to inner surfaces of friction plate
guides to prevent them from falling.

SPD385A

4. Install differential case B over side gear, discs, plates, spacer


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 plate from the hexagonal part
of the side gear.

SPD386A

5. Install pinion mate gears and pinion mate thrust washers on pin-
ion mate shaft, then install pinion mate shaft in differential case
B.
6. Install side gear to pinion mate gears.

SPD426

7. Install each disc and plate.


● Use same procedures as outlined in steps 1 through 4 above.

SPD387A

8. Install differential case A.


● Position differential cases A and B by correctly aligning marks
stamped on cases.

SPD388A

RFD-66
REAR FINAL DRIVE ASSEMBLY
[H233B]
9. Tighten differential case couple bolts.
A
Differential case couple : 64 - 74 N·m (6.5 - 7.5 kg-m,
bolts 47 - 54 ft-lb)
10. Place ring gear on differential case and tighten ring gear bolts. B
Tool number KV10112100 (BT-8653-A)
Ring gear bolts
C
Step 1 : 53.9 - 63.7 N·m (5.5 - 6.4 kg-m,
40 - 46 lb-ft)
SPD364A
Step 2 : 34° - 39° degrees rotation RFD
● Tighten bolts in a crisscross pattern.

11. Install side bearing inner race.


12. Check differential torque. Refer to RFD-54, "Checking Differential Torque" . E

INSTALLATION OF DRIVE PINION ASSEMBLY


1. Press-fit front and rear bearing outer races with Tools.
F
Tool number A: ST30611000 (J25742-1)
Tool number B: ST30621000 (J25742-5)
Tool number C: ST30613000 (J25742-3) G

L
SPD580

2. Select drive pinion height adjusting washer. Refer to RFD-72, M


"Drive Pinion Height Adjustment" .
3. Install drive pinion adjusting washer in drive pinion, and press-fit
pinion rear bearing inner cone in it, with press and Tool.
Tool number : ST30901000 (J-26010-01)

SPD377

RFD-67
REAR FINAL DRIVE ASSEMBLY
[H233B]
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 A: ST30720000 (J-25405)
Tool number B: KV38102510 ( — )

SPD291A

6. Install drive pinion bearing spacer, pinion bearing adjusting shim


and drive pinion in gear carrier.

SPD935-A

7. Install ABS sensor unit and sensor rotor (2WD models).


ABS sensor unit bolt : 8 - 11 N·m (0.8 - 1.1 kg-m,
5.8 - 8.0 ft-lb)
8. Insert companion flange onto drive pinion. Tap the companion
flange with a soft hammer until fully seated

SPD697

9. Tighten pinion nut until total preload is within specification.


● The threaded portion of drive pinion and pinion nut
should be free from oil or grease.
Tool number : KV38108300 (J-44195)
Pinion nut : 127 - 294 N·m (13.0 - 30.0 kg-m,
94 - 217 ft-lb)
Pinion preload : 1.2 - 2.2 N·m (12 - 22 kg-m, 10 -
19 in-lb)
SPD481A

RFD-68
REAR FINAL DRIVE ASSEMBLY
[H233B]
10. Turn drive pinion in both directions several times, and measure
pinion bearing preload using Tool. A
Tool number : ST3127S000 (J-25765-A)
Pinion bearing preload : 1.4 - 1.7 N·m (14 - 17 kg-cm,
(With front oil seal) 12 - 15 in-lb) B
Pinion bearing preload : 1.2 - 1.5 N·m (12 - 15 kg-cm,
(Without front oil seal) 10 - 13 in-lb)
C
If preload is out of specification, adjust the thickness of spacer
and shim combination by replacing shim and spacer with thinner
one. SPD149

RFD
● Start from the combination of thickest spacer and shim.

● Combine each spacer and shim thickness one by one until the correct specification are achieved.

Drive pinion bearing : Refer to RFD-73, "Drive E


preload adjusting Pinion Preload Adjust-
spacer and shim ment" .
F
INSTALLATION OF DIFFERENTIAL CASE

1. Install differential case assembly with side bearing outer races into gear carrier.
G
2. Position side bearing adjusters on gear carrier with threads
properly engaged; using Tool, screw in adjusters lightly at this
stage of assembly.
H
Tool number : ST32580000 (J-34312)

J
SPD684

3. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier. K
● Do not tighten at this point. This allows further tightening of
side bearing adjusters.
L

SPD265

4. Tighten both right and left side bearing adjusters alternately 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.
Ring gear-to-drive pinion : 0.13 - 0.18 mm (0.0051 -
backlash 0.0071 in)

SPD246

RFD-69
REAR FINAL DRIVE ASSEMBLY
[H233B]
● When checking preload, turn drive pinion in both direc-
tions several times to set bearing rollers using Tool.
Tool number : ST3127S000 (J-25765-A)
Total preload : 1.7 - 2.5 N·m (17 - 25 kg-cm,
15 - 22 in-lb)

SPD149

5. Tighten side bearing cap bolts.


Side bearing cap : Refer to RFD-48, "Compo-
bolts nents" .
6. Install side lock finger in place to prevent rotation during opera-
tion.

SPD698

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


Ring gear runout limit : 0.08 mm (0.0031 in)
● If backlash varies excessively in different places, the variance
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 differential
case should be replaced.
8. Check tooth contact. Refer to RFD-63, "TOOTH CONTACT" .
SPD247

RFD-70
SERVICE DATA AND SPECIFICATIONS (SDS)
[H233B]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
A
General Specifications EDS00135

2WD MODEL
Engine VG33E VG33ER B
Vehicle grade XE SE SC
Standard Optional* Standard Standard
Rear final drive H233B C
2-pinion LSD 2-pinion LSD LSD
Gear ratio 4.636 4.900 4.363
RFD
Number of teeth (Ring gear/drive pinion) 51/11 49/10 48/11

Oil capacity (Approx.) (US pt, lmp pt) 2.8 (5-7/8, 4-7/8)
*: Standard on Canada models.
E

4WD MODEL
Engine VG33E VG33ER F
Vehicle grade XE SE SC
Standard Optional Standard Optional* Standard
G
Rear final drive H233B
2-pinion LSD 2-pinion LSD LSD
Gear ratio 4.636 4.900 4.900 4.900 H
Number of teeth (Ring gear/drive pinion) 51/11 49/10 49/10 49/10

Oil capacity (Approx.) (US pt, lmp pt) 2.8 (5-7/8, 4-7/8)
I
*: Standard on Canada models.

Ring Gear Runout EDS00136

J
Ring gear runout limit mm (in) 0.08 (0.0031)

Side Gear Adjustment EDS00137

K
Side gear backlash (Clearance between side gear thrust washer and dif-
0.10 - 0.20 (0.0039 - 0.0079)
ferential case) mm (in)

Available Thickness mm (in) Part number*


L
side gear 1.75 (0.0689) 38424-T5000
thrust wash- 1.80 (0.0709) 38424-T5001
ers 1.85 (0.0728) 38424-T5002
*Always check with the Parts Department for the latest parts information.
M

Differential Torque Adjustment (LSD Models) EDS00138

Differential torque N·m (kg-m, ft-lb) 40 - 58 (4.0 - 6.0, 29 - 43)


Number of discs and plates
Friction disc 2
Friction plate 5
Spring plate 2
Spacer 1
Wear limit of plate and disc mm (in) 0.1 (0.004)
Allowable warping of friction disc and
0.8 (0.0031)
plate mm (in)
Total thickness mm (in) 18.57 - 20.43 (0.7311 - 0.8043)

RFD-71
SERVICE DATA AND SPECIFICATIONS (SDS)
[H233B]
Part name Thickness mm (in)) Part number*
38433-C6004
1.4 (0.055)
(adjusting type)
Friction disc
38433-C6002
1.5 (0.059)
(standard type)
38433-C6003
1.6 (0.063)
Available discs and plates (one side) (adjusting type)
1.4 (0.055) 38432-C6002
Friction plate 1.5 (0.059) 38432-C6001
1.6 (0.063) 38432-C6003
Spring plate 1.5 (0.059) 38435-S9200
Spacer 6.0 (0.236) 38454-S9200
*Always check with the Parts Department for the latest parts information.

Total Preload Adjustment EDS00139

Total preload N·m (kg-cm, in-lb) 1.7 - 2.5 (17 - 25, 15 - 22)
Ring gear to drive pinion backlash mm (in) 0.13 - 0.18 (0.0051 - 0.0071)
Side bearing adjusting method Side adjuster

Drive Pinion Height Adjustment EDS0013A

Thickness mm (in) Part number*


2.58 (0.1016) 38151-01J00
2.61 (0.1028) 38151-01J01
2.64 (0.1039) 38151-01J02
2.67 (0.1051) 38151-01J03
2.70 (0.1063) 38151-01J04
2.73 (0.1075) 38151-01J05
2.76 (0.1087) 38151-01J06
2.79 (0.1098) 38151-01J07
2.82 (0.1110) 38151-01J08
2.85 (0.1122) 38151-01J09
2.88 (0.1134) 38151-01J10
2.91 (0.1146) 38151-01J11
2.94 (0.1157) 38151-01J12
2.97 (0.1169) 38151-01J13
3.00 (0.1181) 38151-01J14
3.03 (0.1193) 38151-01J15
Available 3.06 (0.1205) 38151-01J16
pinion height 3.09 (0.1217) 38151-01J17
adjust wash- 3.12 (0.1228) 38151-01J18
ers 3.15 (0.1240) 38151-01J19
3.18 (0.1252) 38151-01J60
3.21 (0.1264) 38151-01J61
3.24 (0.1276) 38151-01J62
3.27 (0.1287) 38151-01J63
3.30 (0.1299) 38151-01J64
3.33 (0.1311) 38151-01J65
3.36 (0.1323) 38151-01J66
3.39 (0.1335) 38151-01J67
3.42 (0.1346) 38151-01J68
3.45 (0.1358) 38151-01J69
3.48 (0.1370) 38151-01J70
3.51 (0.1382) 38151-01J71
3.54 (0.1394) 38151-01J72
3.57 (0.1406) 38151-01J73
3.60 (0.1417) 38151-01J74
3.63 (0.1429) 38151-01J75
3.66 (0.1441) 38151-01J76
*Always check with the Parts Department for the latest parts information.

RFD-72
SERVICE DATA AND SPECIFICATIONS (SDS)
[H233B]
Drive Pinion Preload Adjustment EDS0013B

A
Drive pinion bearing preload adjusting method Adjusting shim and spacer
Drive pinion preload without front oil seal N·m (kg-cm, in-lb) 1.2 - 1.5 (12 - 15, 10 - 13)
Drive pinion preload with front oil seal N·m (kg-cm, in-lb) 1.4 - 1.7 (14 - 17, 12 - 15) B
Thickness mm (in) Part number*
2.31 (0.0909) 38125-82100
2.33 (0.0917) 38126-82100 C
2.35 (0.0925) 38127-82100
2.37 (0.0933) 38128-82100
Available 2.39 (0.0941) 38129-82100
2.41 (0.0949) 38130-82100 RFD
front drive
pinion bear- 2.43 (0.0957) 38131-82100
ing adjust- 2.45 (0.0965) 38132-82100
ing shims 2.47 (0.0972) 38133-82100 E
2.49 (0.0980) 38134-82100
2.51 (0.0988) 38135-82100
2.53 (0.0996) 38136-82100
2.55 (0.1004) 38137-82100 F
2.57 (0.1012) 38138-82100
2.59 (0.1020) 38139-82100
Thickness mm (in) Part number*
Available G
drive pinion 4.50 (0.1772) 38165-76000
bearing 4.75 (0.1870) 38166-76000
adjusting 5.00 (0.1969) 38167-76000
spacers 5.25 (0.2067) 38166-01J00 H
5.50 (0.2165) 38166-01J10
*Always check with the Parts Department for the latest parts information.
I

RFD-73
SERVICE DATA AND SPECIFICATIONS (SDS)
[H233B]

RFD-74

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