differential DATSUN PICK-UP 1977 User Guide

PROPELLER
SHAFT
DIFFERENTIAL

CARRIER

Condition
Probable

cause

Knocking
sound

during

starting
or
noise

during

coasting
on

propeller

shaft
Worn

damaged
universal

joint

Worn
sleeve

yoke
and

main
shaft

spline

Loose

propeller
shaft
installation

Loose

joint
installation

Damaged
center

bearing
or
insulator

Loose
or

missing
bolts
at

center

bearing

bracket
to

body

Scraping
noise
Dust

cover
on
sleeve

yoke
rubbing
on

transmission
rear
extension
Dust

c
ver
on

companion

flange
rubbing
on
differ
mtial

carrier

Whine
or
whistle

Damaged
center

bearing
Corrective

action

Replace

Replace

Retighten

Adjust
snap
ring

Replace

Replace
or

tighten
bolts

Straighten
out
dust
cover
to

remove

inter

ference

Replace

DIFFERENTIAL
CARRIER

TYPE
H190

CONTENTS

DESCRIPTION

REMOVAL

PRE
DISASSEMBLY
INSPECTION

DISASSEMBLY

INSPECTION

ASSEMBLY
AND

ADJUSTMENT

PRECAUTIONS
IN
REASSEMBLY

ASSEMBLY
OF
DIFFERENTIAL
CASE
PD
5

PD
7

PD
7

PD
7

PD
8

PD

PD
8

PD
8

DESCRIPTION

The

differential

carrier
on
the
620

series

has
a

gear
ratio
of
4
37S

The
drive

pinion
is

rnounted
in
two

tapered
roUer

bearings
which

are

pre

loaded

by
pinion

bearing
adjusting

spacer
and
washer

during
assembly

The
drive

pinion
is

positioned

by
a

washer
located

between
a
shoulder
of
ASSEMBl
Y

OF
DIFFERENT
Al

CASE

ADJUSTMENT

OF
DRIVE
PINION

HEIGHT

ADJUSTME
NT
OF
DRIVE

PINION

PRELOAD

t

ADJUST
ENT

OF
SIDE
8EARING

SHIMS

INSTAllATION

REPLACEME
NTOF
FRONT
Oil
SEAL

the
drive

pinion
and
the
rear

bearing

The
differential

case
is

supported
in

the
carrier

by
two

tapered
roller

side

bearings
These

are

preloaded

by
in

serting
shims
between

the

bearings
and

the
differential

case
The
differential

case

assembly
is

positioned
for

proper

ring
gear
and
drive

pinion
backlash

by

PO
5
PD
8

PD
9

PD
lO

PD
11

PD
13

PD
13

varying
these

shims
The

ring
gear
is

bolted
to
the

differential
case
The

case
houses
two
side

gears
in

mesh

with
two

pinion
mates

mounted
on
a

pinion
shaft
The

pinion
shaft
an

chored
in

the
case

by
lock

pin
The

pinion
mates
and
side

gears
are
backed

by
thrust
washers

The

carrier

is
of

malleable
cast
iron

PROPEllEff
SAAFT
8
DifFERENTIAL
CARRIER

TYPE
H19O

Q
@

4
1
Drive
pinion
nu
t

2
Companion
flange

3
Oil
al

@
4
Front
bearing

5
DIive
pinion
bearing
adjusting
washer

Adjust
pinion
bearing
preload
by

@
ecting
@
and

@

6
Drive
pinion
beating
spacer

1
Drive

pinion

8
Rem
bearing

@
9
Drive
pinion
adjusting
wamer

10
loci
pin

11
Side
bearing
adjusting
mint

@
Adjust
side
bearing
preload
and

@@
backlash
betwam
ring
geu

and
cIrive

pinion
by
ting
@

@
12
Side
bearing

13
Side
gear

14
nUust
washer

Adjust
pinion
mate
to
side

gear

backlash
Of
the
clearance

between
the
teat
face
of
side

gear
and
ttuust
washer
to
0
02
to

@
0
08
nun
0
0008
10
0
0031
in

by@

15
Differential
cast

16
Thrust
washer

@
17
Pinion
mate

18
Pinion
sbaft

19
Ring
gear

Backlam
between
ring
gear

and
drive
pinion

0
t5
to
0
20
nun

0
0059
10
0
0079
in

20
Bearing
cap
boll

21
Thrust
block

22
Ring
gear
bolt

23
Lock
strap

Tightening
torque
f
of

@
bollS
and
nut

kg
m
ft
lb

@T
14
0
to
t7
0
101
to
123

L
@T
4

0
to
5
0
29
10
36

@T

7

0108
0
5110
58

L
198
4010
198
55
nun

1
8110107
8169
in

P0229

Fig
PD
6
cro
ectional
uiew
of
differenwl
carner

PD
6

PROPELLER
SHAFT
DIFFERENTIAL
CARRIER

REMOVAL

I
Jack

up
rear
of
vehicle
and

sup

port
it

by
placing
a

safety
stand
under

rear
axle
case
Drain

gear
oil

2
Remove

propeller
shaft
and
rear

axle
shafts
These
works
can
be
done

by
referring
to
Rear
Axle
and
Rear

Suspension

3
Loosen
off
bolts

securing
differ

ential
carrier
to
rear
axle
cas
and

take
out
differential
carrier

assembly

PRE
DISASSEMBLY

INSPECTION

Differential
carrier

should
be
in

spected
before

any

parts
are
removed

from
it

These

inspections
are

helpful
to

fmd
the

cause
of
a

problem
and

to

determine
the
corrections

needed

I

Mount
differential
carrier
on
Dif

ferential
Attachment
ST063
I
0000

ST063
10000

Fig
PD
7

Holding
differential
can
ier

2

Visually
inspect
parts
for
wear
or

damage

3

Rotate

gears
to
see
if
there
is

any

roughness
which
would
indicate
dam

aged
bearings
or

chipped
gears
Check

the

gear
teeth
for

scoring
or

signs
of

abnormal
wear

Measure

preload
of

drive

pinion
See

Figure
PD
19

4

Set

up
a
dial
indicator
and
check

the
backlash
at
several

points
around

ring
gear
Backlash
should
be
0
15

to

0
20
mOl
0
00S9
to
0
0079
in

S
Check
the

gear
tooth
contact

with
a
mixture
of
ferric
oxide
and

g
ar
oil
to
all

ring
gear
teeth

For
the
tooth
contact

pattern
see

paragraph
dealing
with
tooth
contact

pattern
adjustment
DISASSEMBLY

I
Put
match

tpark
on
side

bearing

caps
and
carrier
and

remove
side

bearing
caps
and
take
out

differential

case
assembly

P0203

Fig
PD

B
Removing
differenlwl

case
assem

bly

Note
Care

should
be

taken
not
to

confuse
the
left
and

right
hand

bearing

caps
and

bearing
outer
race

so
that

reassembly
will
be

easily

carried
out
with
the
same
parts
in

the

original
position

2
Remove

drive

pinion
nut

using

Drive
Pinion

Flange
Wrench

ST31530000
and

pull
off

companion

flange
using
a
standard

puller

Fig
PD
9

Removing
drive

pinion

nul

3

Extract
drive

pinion
assembly
to

the
rearwards

by
tapping
the
front
end

with
a
soft
hammer
Drive

pinion
can

be
taken
out

together
with
rear
bear

ing
nner
race

bearing
spacer
and

washer

4
Remove
oil
seal
and
take
out

front

bearing
inner
race

Note
Oil
seal
must
not
be
used

PD
7
5

Hold
rear

bearing
inner

race
with

Drive

Pinion
Rear

Bearing
Inner

Race

Puller
ST30031000
and
extract
from

drive

pinion
with
a

press

STJ0031000

PD205

Fig
PD
10

Removing
pinion
rear

bearing
inner
race

6
To

remove
outer
races
of
both

front
and
rear

bearing
apply
a

brass

drift
to

race
side
surface
and
with

draw

them

by
tapping
the

top
of
drift

with
a
hammer

Fig
PD
l1
Removing

pinion
front
and

rear

bearing
outer
races

Dissssembly
of
dHferentIeI

case

1
When

replacing
side

bearing
use

Differential
Side
Bearing
Puller
Set

ST3306S00
I

set
of
ST330S100
I

and

ST33061000

Fig
PD
12

Removing
ide

bearing

PROPElli

ER
SHAfT
DIFFERENTIAL
G

ARRIERf

Notes

a
PUller
should
be
handled
with

care

in

catchins
the

edge
of

bearing

inner

race

b
Be
careful

not
to

confuse
left
and

right
hand

parts

2
Remove

ring

gear
by
spreading

out
lock

strap
and

loosening
ring
gear

bolts
in

diagonally

3

Punch
off

pinion
mate

shaft
lock

pin
from

ring

gear
side

using
Solid

Punch
ICV31100300

KV31100300

PD022

Fig
PD

13

Removing
lock

pin

Note

Lock

pin
i
cauIked
at

pin
hole

mouth
on
differential
case

Do
not

punch
it
off

forCibly
without

checkins
how
it
is
uIked

4

Draw

out

pinion
shaft
and

re

move
thrust

block

pinion
mates
side

gears
and

thrust
washers

Note
Put
marks

on

gear
and
thrust

Wasliersotliat

they
can
be
reinstaD

ed
in

their

original
positions
from

which

they
were
removed

INSPECTION

Thoroughly
clean

all
disassembled

parts
and
examine

them
to
see
if

they

8re

worn

damaged
or
otherwise

faulty
and

how

they
are
affected

Repair
or

replace
ail

faulty

parts

whichever
is

necessaiy

I

Check

gear
teeth
for

scoring

cracking
and

chipping
and

make
sure

that

tooth
contact

pattern
indicates

correct

meshing
depth
If

any
fault
is

evident

replace
parts
as

required
Note
Drive

pinion
and

ring
gear
are

supplied
for

replacement
as
a
set

therefore

should
either

part
be

damaged
replace
as
a
set

2

Check

pinion
shaft
and

pinic
m

mate
for
scores

and

signs
of
wear
and

replace
as

required

Follow

the
same

procedure
for

side

gear
and
their
seats

on
differential

case

3

Inspect
all

bearing
races
and

rollers
for

scoring
chipping
or
evi

dence
of
excessive
wear

They
should

be
in

tiptop
condition
such
as
not

worn
and

with
mirror
like

surfaces

Replace
if
there
is
a
shadow

of
doubt

oil

their
efficiency
as
an
incorrect

bearing
operation
may
result
in
noises

and

gear
seizure

4

Inspect
thrust

washer
faces

Small

faults
can

be
corrected
with

sand

paper
If

pinion
mate

to
ide

gear

backlash
or

the
clearance

between

side

gear
and
thrust
washer
exceeds

limits
0

02

to
0
08
nun
0
0008
to

0
0031
in

replace
thrust
washers

S

Inspect
carrier

and
differential

case
for
cracks

or
distortion

If
either

condition
is

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

reo

verse

order
of

disassembly
The
foDow

ing
directions
for

adjustment
and

usage
of

special
tools
enable
to

obtain

a

perfect
differential

operation

PRECAUTIONS
IN

REASSEMBLY

I

Arrange
shims
w

shers
and
the

like
to
install
them

correctly

2

Thoroughly
clean

the
surfaces
on

which
shims

washers

bearings
and

bearing

caps
are
installed

3

Apply
gear
oil

when

installing

bearings

4

Pack

grease
cavity
between

lips

when

fitting
oil
seal

PD
8
ASSEMBLY
OF

DIFFERENTIAL
CASE

I

Assemble

pinion
mates
side

gears
thrust
block
and

thrust
washers

in
differential

case

2
Fit

pinion
shaft
to
differential

case
so

that
it

meets
lock

pin
holes

3

Adjust

pinion
mate

to
ide

gear

backlash
or
the
clearance

between
the

rear
face
of

side

gear
and
thrust

washer
to
0
02
to

0
08
mOl
0
0008

to
0

0031
in

by

selecting
side

gear

thrust
washer

Side

gear
thrust

WlISber

Thickness

nun

in

Over

0
7S

to
0
80

0
029S
to
0
03IS

Over

0
80
to
O
8S
Om

IS
to
0
033S

Over

0
8S
to
0
90
0

033S
to
0
03S4

Over

0
90
to
0
9S
0
03S4

to
0
0374

4

Lock

pinion
shaft
lock

pin
using
a

punch
after
it

is
secured
into

place

S

Apply
oil
to

gear
tooth

surfaces

and
thrust
surfaces
and
check
if

they

turn

properly

6
Place

ring

gear
on

differential

case

and
install

bolts
and
lock
washers

Torque
bolts
to

specification
and

bend

up
lock

strap

Tightening

torque

7
0
to
8
0

kg
m

S1to
Sifft
Ib

Notes

ao
Use

only
genuine
ring
gear
bolts

and
new
lock

strap

b

Tighten
bolts
in

criss
cross
fashion

lighdy
tapping
fOund
bolt

heac
Js

with
a
hammer

7

When

replacing
side

bearing

measure

bearing
width

using
a

stand

ard

gauge
20
00
nun
0
7874
in

thickness
and
a

weight
block
2
5

kg

S
S
Ib

prior
to
installation
See

Figure
PD

I4

Standard
bearing
width

20
00
nun
0
7874
in

PROPELLER
SHAFT
DifFERENTIAL
CARRIER

Standard

gauge
I

1

Fig
PD
14

Me
uring
bearing
width

8
Press
fit
side

bearing
cone
into

differential
case

using
Differential
Side

Bearing
Drift
ST33230000
and

Adapt

er

ST33061000

t
J

I
ST33230000

io
o1

P0244

Fig
PD
15
ln

talling
side

bearing

cone

ADJUSTMENT
OF
DRIVE

PINION
HEIGHT

Adjust
the

pinion
height
with

washer

provided
between
rear

bearing

inner

race

a
ld
the
back
of

pinion

gear

Press
fit
front
and
rear

bearing

outer
races
into

gear
carrier

using

Drive
Pinion
Ou
ter

Race
Drift

Front

ST306
I
1000
and

Sf30613oo0
Rear

ST306
II

000
and

ST3062I

000

2

Fit
rear

bearing
on
carrier
and

install

Dummy
Shaft
Sf3
I

942000
and

Collar
ST3197oo00
on
rear

bearing

and

place
H

eight
Gauge
ST31941000

on
carrier

ST31941000

PD2
b

Fig
PD
16

Adjusting
pinion
height

3

Measure
the
clearance

N
be

tween

the

tip
end
of

height
gauge
and

the

end
surface
of

dummy
shaft

using

a
thickness

gauge

P0235

Fig
PD
17

Measuring
clearance

4
Tlie

thickness
of
drive

pInIOn

height

adjusting
wa

sh
ers
can
be
ob

tained
from
the

following
formula

T
N

H
0

S
x
0
01

2
18

PD
9
Where

T

Required
thickness
of
rear

bearing

adjusting
washers
mOl

N
Measured
value

with
thickness

gauge
mOl

H

Figure
marked
on
the
drive

pinion

head
See

Figure
PD
18

0
Figure
marked
on
the

dummy

shaft

S
Figure
marked
on
the

height

gauge

Figures
for
H
0
and

S
are
dimen

sional
variations
in

a
unit

of
1

100
mOl

against
each
standard

measurement

Head

number

HI

P0186
Set
numbl
r

Fig
PD
18
Variation
number
on

drive

pinion

Examples
of
calculation

Ex
I

N
0

5Imm
H
2
0

1

S
O

T
N

H
D
S
xO
01

2

18

0
51
2
I
0

x
O
ol
2
18

O
SI
2

t
1
0
x
0

01

2
18

0
51
3
x
0
01
2

18

0
51
0
03
2
18

2

66
mOl

The
correct
washer

is
2
67
mm

thick
See

following
table
for
drive

pinion
adjusting
washer

PROPELLER
SHAFT

DIFFERENTIAL
CARRIER

Ex
2

N

O
68mm
H
3
D

I

S
2

T

N
H
0

S
x

0
01

2
18

0
68
3

1
2

x
Om
2
18

0

68
3
1

2
x
0

01

2
18

0
68
2
x

0
01
2
18

0
68
0
02
N8

0
68

0
02
2

18

i
88

mm

The
correct

washer
is
2
88

mm

thick

Ex
3

N
0

70mm
H
O
0

0

S
O

T

N

H
0
S
x
0
01

2
18

0

70
0
0
0
x

0
01

2

18

0
70
0
x

0
01
2
18

0
70

0
2
18

0
70
2
18

2
88

mm

The

correct
washer
is
2
88

mm

thick

Note
If
lues

signifying
H
D

and
S

are
not

given

regard
them
as
zero

and
n
C

r
e
After

assembly

check
to
see
that

tooth
contact

is

correct
If
not

readjust
For
the

tooth
contact

pattern
see

page

PJ
12
for
Contact
Pattern
Drive

pinion
adjusting
washer

Thickness
mm
in

2
58
0

1016

2
61
0

1028

2

64
0
1039

2

67
0
1051

2
70
0
1063

2
73
0
107S

2
76
0
1087

2
79
0

1098

2
82
0
1110

2
85
OJ
122

2
88
OJ
134

2
91
0
1146

2

94
0
1IS8

2
97
0
1169

3
00

0
1181

3
03
0
1
193

3
06
0
1205

3
09
0
1217

3
12
0
1228

3
IS
0
1240

3
18
0
I2S2

S
Fit

determined
drive

pinion
ad

justing
washer
in
drive

pinion
and

preSs
fit

rear

bearing
inner

race
in
it

using
Base

ST30901000

ADJUSTMENT
OF
DRIVE

PINIONPI
IELOAD

AdjUst
the

preload
of
drive

pinion

with

spacer
and
washer
between
front

and
rear

bearing
inner

races

This

procedure
has

nothing
to
do

with
thickness

of
drive

pinion

adjust

ing
washer

This

adjustment
must
be
carried

out
without

oil
seal
inserted

I

Lubricate

pinion
front
and

rear

bearings
Install
drive

pinion
in

gear

carrier

Be
sure
that

spacer
t
washer

front

bearing
inner

race

Companion

flange
and
flat
washer
are
fitted

on

pinion
Tighten
nut
to

specified
torque

and
confum

preload

Tightening
torque

14
0
to
17
0

kg
m

101
to
123
ft

lb

PD
l0
Note

Replace

bearing
washer
and

spacer
with

thicker
ones
if

pinion

cannot
be
turned

by
hand
while
it

is

heing
tightened

2

Measure
pinion
bearing

prelo
d

using
Preload

Gauge
ST3I
27S000
and

select
washer
and

spacer
that
will

provide

required

preload

Preload

without
oil
seal

10
0

to
13
0

kg
cm

8
7

to
II
in

lb

At

companion

flange
bolt
hole

2
9

to

3
7

kg

6
4
to8

2Ib

Note
Preload
of
old

bearing
is
the

same
value

as
that
of

a
new

bearing

Fig
PD
19

Measuring
pinion
preload

Pinion

bearing
adjusting
spacer

Length
mOl
in

S4
50

2
14S7

S4
80
2
IS7S

SS
IO
2
1693

5S
40
2
1811

SS
70
2
1929

S6
00
2
2047

PROPELLER
SHAFT
DIFFERENTIAL
CARRIER

Drive

pinion
bearing
adjusting
washer

Thickness
mm

in

over
3
80

to
3
82
0

1496
to
O
lS04

over
3
82

to
3
84
O
lS04

to
0
ISI2

over
3
84
to
3
86
O
lSI2

to
0
IS20

over
3
86
to
3
88

O
lS20
to
O
IS28

over

3
88
to
3
90
O
lS28
to
0
IS3S

over
3
90
to

3
92
0
IS3S
to
O
IS43

over
3

92
to

3
94
0
IS43
to
O
lSS
I

over
3

94
to
3
96
O
lSSI
to
O
lS59

over
3

96
to
3
98
O
lSS9

to
0
IS67

over
3
98

to
4

00
O
lS67
to
O
lS7S

over

4
00
to
4
02
0
S7S
to

O
lS83

over

4
02
to
4
04
O
lS83
to
0
IS91

over

4
04
to
4
06
O
lS9I
to
0
IS98

over

4
06
to
4
08
O
lS98
to
0
1606

over
4

08
to
4
10
0
1606
to

0
1614

3
Check
and

adjust
tooth
contact

pattern
when

former

adjustment
of

bearing

preload
is

completed
Unless

anything
wrong
is

found
remove
drive

pinion
nut
and

companion
flange
and

press
n
oil
seal
into

gear
carrier

using
Oil
Seal

Fitting
Tool

KV38I02SS0

Apply
grease
cavity
be

tween
seal

lips

4

Again
install

companion
flange

and
washer
and

tighteh
nut
to

speci

fied

torque
14
0

to
17
0

kg

m
IO
to

123
ft
lb

S
Measure

preload
again

Preload
with
oil
seal

I
1

0
to
14

0

kg
cm

9
S

to
12
in
lb

At

companion
flange
bolt
hole

3
1
to
4
0

kg

6
8
to
8
81b

ADJUSTMENT
OF
SIDE

BEARING
SHIMS

I
If

hypoid
gear
set
carrier
dif

ferential
case
or
side

bearing
has
been

replaced
with
new
one

adjust
the
side

bearing
preload
with

adjusting
shim

The

required
thickness
of

adjusting

shim
can
be
calculated

by
the
follow

ing
formulas
T
A

C
D
H

xO
OI

O
l7S
E

T2
B
D
H
xO
OI

O
ISO
F

Where

T

1
Required
thickness
of
left
side

bearing
adjusting
shim
mm

T

2
Required
thickness
of

right
side

bearing

adjusting
shim
mm

A

Figure
marked

on
the

left
side

bearing
housing
of

gear
carrier

B

Figure
marked
on
the

right
side

bearing
of

gear
carrier

C
0

Figure
marked
on
the
differ

entia
case

E
F
These

are
differences
in
width

of
left
or

right
side

bearing
against

the
standard
width
20
00
mOl

mOl

If

bearing
width
is
19
89
the

differ

ence
will
be
as
follows

20
00
19
89
0
11

H

Figure
marked
on
the

ring

gear

See

Figures
PD

20
and
PD
2
I

Figures
for
A

B
C
0
and
H

are

dimensional
varia
tions
in
a
unit

of

1

100
mm

against
each
standard

meas

urement

f
@
a

rj

71

Markj
Mark
B

Mark
C
0

P0214

Fig
PD
20
Thickn
of
shim
on
l

ft

and

righ
t
sides

Fig
PD
21
Variation
number
on

ring
gear

PD
ll
Examples
of
calculation

Ex
I

A
I

B
2
C
2
0

3

E
0
11
mm
F

O
IS
mm

H
2

Left
side

T
A

C
0
H
x

0
01

O
liS

E

1
2
3

1
x

0
01

0
17S
0
11

1
2
3

2
x

O
O

O
l7S
0
11

4

x
0
01
0
175
0
11

0
04
0
1
7S

0
11

0
32S
mOl

The
correct
shims
are
as
follows

Thickness

0
07

0
20
Quantity

x
2
0

14

x
I
0

20

Total
thickness
0
34
mOl

Right
side

T2
B

0
H
x

0
01

O
lSO
F

2
3
2
x

0
01

O
ISO
0
15

2

3
2
x
0

01

O
ISO
0
15

3
x
O
OI
O
ISO
O
IS

0

03
O
lSO
O
lS

0
27
mm

The
correct
shims
are
0
07

plus

0
20
mm
thick

PROPELLER

SHAFf
DIFFERENTIAL

CARR
IER

Ex

2

A

0
B
3

C
I

0

0

E
0

20
mOl
F

0
17
mOl

H
2

Left
side

T

I
A
C

D
H
x
om

0

17S
E

0
I

0
2
x
0
01

0
I7S

0
20

0
I
0
2

x
0

01

0
17S
0
20

3

Om
0
17S

0
20

0
03
0
17S
0
20

O

34S
mrn

The
correct

shinjs

are
O

OS

plus

0
10

plus
0
20
mrn
thick

Right
side

T2
B
D
H

xO
0l

O
ISO
F

3
0
2
x

om

O
ISO

0
17

3

0

2
x

om

0
150
0
17

S
x
0
01

0
ISO
0
I7

O
OS

0
1S0
0
17

0
37

mrn

The

correct
shims
are
0
07

plus

0
1
0

plus
0

20
mm
thick

Note
If

w1ues

signifying
A

B
C
0

and

H
are
not

given
regard
them

as

zero
and

compute

Aft
assembly
check
to

see
that

preload
and
backlash

are
correct
If

not

readjust

Side

bearing

adjusting
shim

Thickness
mm
in

O
OS
0
0020

0
07
0
0028

0
1

0
0
0039

0
20
0
0079

0
50
0
0197
2

Fit
determined

side

bearing

adjusting
shim
on
differential
case
and

press
fit
left

and

right
side

bearing

inner

races
on
it

using
Side

Bearing

Drift
ST33230000
and

Adapter

ST33061000

3

Install
differential

case

assembly

into

gear
carrie

tapping
with
a
rubber

mallet

4

Align
mark

on

bearing
cap
with

that
on

gear
carrier

and
install

bearing

cap
on
carrier
And

tight
n
bolts
to

specified
torque

Tightening

torque

4
0
to
S
O

kg
m

29
to
36
fHb

S

Measure

ring

gear
to
drive

pinion

backlash

If
backlash
is
too

small
remove

shims
from
left
side
and

add
them
to

right
side
To
reduce

backlash
remove

shims
from

right
side
and

add
them
to

left

side

Backlash

O
1S
to
0
20

mrn

0
00S9
to
0
0079
in

Fig
PD

22

Mccuuring
back1aah

6
At

the
same
time

check

side

bearing
preload

Bearing
preload

should

read
12

0
to
20
0

kg
cm
10
to

17

in
lb
of

rotating
torque
3
S

to

S
8

kg
7
7

to
12
8

Ib
at

ring

gear
bolt

hole

PD
12
If

preload
does

not
accord
with

this

specification
adjust
it

with
side
bear

ing
shims

7

Check
and

adjust
the
tooth

con

tact

pattern
of

ring
gear
and

drive

pinion

I

Thoroughly
clean

ring
and
drive

pinion

gear
teeth

2
Paint

ring
gear
teeth

lightly
and

evenly
with
a

mixture
of
ferric

oxide

and

gear
oil

to

produce
a
contact

pattern

3
Rotate

pinion
through
several

revolutions
in

the
forward

and
reverse

directions
until

a
defmite
contact

pat

tern
is

developed
on

ring

gear

4
When

contact

pattern
is

incor

rect

readjust
thickness
of

adjusting

washer

S

Incorrect
contact

pattern
of

teeth
can
be

adjusted
in
the

following

manner

a
Heel
contact

To
correct
increase
thickness
of

pinion
height

adjusting
washer

in
order

to

bring
drive

pinio
close
to

ring

gear

P0193

Fig
PD
23
Hul

contact

b
Toe
contact

To

correct
reduce
thickness
of

pinion
height

adjusting
washer
in
order

to
make

drive

pinion

go
away
from

ring

gear

P0194
1

Fig
PD
24
To
contact

P
ROPELLER
SHAFT
DIFFERENTIAL
CARRIER

c
Flank
oontact

Adjust
in

the
same
manner
as
in

b

cV

t

PD195

Fig
PD
25
Flank
contact

d
Face
contact

Adjust
in
the

same
manner
as
in

a

P0196
t

Fig
PD
26
Face

contact

e
Correct
tooth
contact

Fig
PD
27
Correct

contact

Note

Change
in
thickness
of

adjWll

ing
washer
is

accompanied
by

change
in
backlash
Oled
it
when

instaIIi
gear
INSTALLATION

Installing
can
be

done
in
the
reverse

order
of
removal

Tightening
torque

Gear
carrier
to
rear
axle
case

1
7

to
2
5

kg
m

12
to
18
ft
lb

Drain
and
filler

plug

6
0
to
10
0

kg
m

43
to
72
ft
lb

Gear
oil

capacity
1
0
liter

2
US

pt
I
Y

Imp
pt

REPLACEMENT
OF

FRONT
OIL
SEAL

Replacement
of
front
oil

seal
with

d
ifferential
carrier

assembly
installed

on
the
vehicle

When

replacing
front
oil
seal

do
as

follows

1
Drain

gear
oil

2
Raise

the
rear
end
of

vehicle

and

support
it
with

safety
stands

3
Detach

propeller
shaft
from
com

panion

flange
of
carrier

4

R
1
ove
drive

pinion
n
t

holding

companion
flange
with
Drive
Pinion

Flange
Wrench

ST31S30000
P0238

Fig
PD

29
Removing
companion

flange

6
Remove
oil
seal

7
Set

new
oil
seal
in

position
using

Oil
Seal

Fitting
Tool

KV38102SS0

Apply
grease
in
between
seal

lips

8
Fit

companion
flange
and
flat

w

sher
on
drive

pinion
and
secure

them
in

position
by
tightening
nut
to

the

given

torque
confirming
specified

preload
using
Drive
Pinion

Flange

WrencliST31530000

Tightening
torque

14
0

to
17
0

kg

101
to
123
ft
Ib

Pinion

bearing
preload

with
oil
seal

11
0
to
14
0

kg
cm

9
5
to
12
in
lb

At

companion
flange
bolt
hole

3
1
to
4

o
g

6
8
8
8Ib

Notes

a
Preioad
of
old

bearing
is
the
same

value
as
that
of

a
new
bearing

b
If
the
desired
nut

tightening
torque

P0237
can
ot
be
obtained
renew
nut
and

readjust

Fig
PD
28
R

moving
drive

pinion

nut

S
Extract

companion
flange

using
a

standard

puller

PD
13
8
Reinstall

propeller
shaft
and
fill

up
differential
carrier

with

gear
oil

PROPELLER

SHAFT

DIFFERENTIAl

CARRIER

TROUBLE
DIAGNOSES

AND

CORRECTIONS

When
a
differential
carrier
is

sus

pected
of

being

noisy
it
is

advisable
to

make
a

thorough
lest

to
determine

whether
the

noise

originates
in
the

Condition

Noise

on
drive

coast

and
float

Noise
on
turn

Knocking
sound

during

starting
or

gear

shifting
tires

road
surface

exhaust
universal

joint
propeller
shaft
wheel

bearings

engine
transmission

or
differential

carrier

Noise
which

originates
in

other

Probable
cause

Shortage
of
oil

Incorrect
tooth
contact

between

ring
gear

and
drive

pinion

Incorrect
backlash
between

ring
gear
and

drive

pinion

Seized

up
or

damaged
ring

gear
and
drive

pinion

Seized

up
damaged
or

broken
drive

pinion

bearing

Seized

up
damaged
or
broken
side

bearing

Loose
bolts
or
nuts

fIXing
ring
gear
bearing

cap
etc

Seized

up
damaged
or
broken
side
and

pinion
mate

Seized

up
damaged
or
broken

side

gear
and

pinion
thrust
washer

Pinion

mates
too

tight
on

their
shaft

Excessive
backlash

Incorrect

backlash

ring
ar

to
drive

pinion
or
side

gear
to

pinionmate

Worn

gears
or
case

Worn
rear

axle
shaft
and

side

gear
spline

Drjve
pinion

bearing
under

p
reload

Loose
drive

pinion
nut

Loose
bolts

or
nuts

ftxing
ring
gear

bearing

cap
etc

PD

14
places
cannot
be
corrected

by

adjust

ment
or

replacement
of

parts
in
dif

ferential
carrier

Corrective
action

Supply
gear
oil
Rebuild

gear
carrier
if

necessary

Adjust
tooth
contact

or

replace
the

hypoid

gear
set

Adjust
backlash
or

replace
the

hypoid
gear

set

if

necessary

Replace
the

hypoid

gear
set

Replace
the

pinion

bearing
and

faulty

parts

Replace
the

side

bearing
and

faulty
parts

Clamp
them

to

specified

torque
and

replace

faulty
parts

Replace

faulty
parts

Replace

faulty
parts

Replace
faulty
parts

Adjust
backlash

Replace
worn

parts

Replace
worn

parts

Adjust
preload

Repair
or

replace

Clamp
them
or

replace
if

necessary