Professional Documents
Culture Documents
D DRIVELINE/AXLE
B
SECTION
REAR FINAL DRIVE C
RFD
E
CONTENTS
C200 H233B F
RFD-1
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 54 MODELS) .............................................................54
General Specifications ............................................ 54 Total Preload Adjustment ........................................54
Ring Gear Runout ................................................... 54 DRIVE PINION HEIGHT ADJUSTMENT .............55
Side Gear Clearance Adjustment ........................... 54 DRIVE PINION PRELOAD ADJUSTMENT .........56
DIFFERENTIAL TORQUE ADJUSTMENT (LSD
RFD-2
PRECAUTIONS
[C200]
PRECAUTIONS
[C200] PFP:00001
A
Caution EDS000GN
Before starting diagnosis of vehicle, understand trouble symptoms well. Perform correct and systematic
operations. B
Check for the correct installation status prior to removal or disassembly. When mating marks are required,
be sure they do not interfere with the function of the parts they are applied to.
Perform overhaul in clean place. Using a dustproof room is recommended. C
Before disassembly, using steam or white gasoline, etc., completely remove sand and mud from exterior
of unit, and prevent them from entering into unit during disassembly or assembly.
Check appearance of disassembled parts for damage, deformation, and unusual wear. If a malfunction is RFD
detected, replace it with a new one.
As a rule, replace lock pins, oil seals, and bearings with new ones every time they are removed.
Use Nissan Genuine Parts for replacement. E
In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
Clean and flush the parts sufficiently, and blow them dry. F
Be careful not to damage sliding surfaces and mating surfaces.
When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces. G
Always use shop paper for cleaning the inside of components.
Do not use cotton gloves or a shop cloth. Using them may leave lint on the surface of the parts.
H
During assembly, observe the specified tightening torque, and apply new deferential oil, Vaseline, or multi-
purpose grease as specified for each vehicle, when necessary.
Do not reuse drained oil. Discard waste oil after oil changes or treating part in accordance with local laws
and regulations. I
RFD-3
PREPARATION
[C200]
PREPARATION PFP:00002
Description Application
Drift
KV38100500
Installing rear final drive oil seal
a: 80 mm (3.35in)dia.
b: 60 mm (2.36in)dia.
ZZA0811D
Drift
ST33061000
Installing side bearing
a: 38 mm dia.
b: 28.5 mm dia.
ZZA0810D
Drift
ST33230000
a: 51 mm Installing side bearing
b: 41 mm
c: 28 mm
ZZA1046D
SDIA0429J
RFD-4
PREPARATION
[C200]
Description Application
A
NT090 C
Drift RFD
ST30621000 Installing pinion rear outer race
a: 79 mm(3.11in)dia. (use with ST3061100)
b: 59 mm(2.32in)dia.
E
NT073
F
Drift
ST30621000 Installing pinion rear outer race
a: 72 mm(2.83in)dia. (use with ST3061100)
b: 48 mm(1.89in)dia. G
NT073
H
Drift
ST33710000
Removing drive pinion gear
a: 30 mm dia. I
b: 23 mm dia.
SDIA0082J
J
RFD-5
: Applicable
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
NVH Troubleshooting Chart
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
Symptom
Reference page
RFD-6
Tooth surfaces worn Refer to RFD-14
Incorrect baklash Refer to RFD-10
Companion flange excessive runout
Improper gear oil Refer to MA section.
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU sections.
PFP:00003
BRAKES NVH in BR section.
[C200]
EDS000GP
STEERING NVH in PS section.
FRONT OIL SEAL
[C200]
FRONT OIL SEAL PFP:38189
A
Removal and Installation EDS000GQ
REMOVAL
1. Remove Propeller Shaft.
B
2. Put a mark on the end of the drive pinion corresponding to the B
position mark on the final drive companion flange.
CAUTION:
C
When making mating marks, use paint, etc., to avoid
scratching on surface.
RFD
SDIA0270E
E
WPD013
INSTALLATION I
1. Apply multi-purpose grease to oil seal lips. Using a drift (special
service tool) as shown, install oil seal. It should become flush
with case end surface. J
Tool number :KV38100500
CAUTION:
When installing, be careful not to incline oil seal.
K
Discard old oil seal; replace with a new one.
L
WPD014
SDIA0270E
RFD-7
REAR FINAL DRIVE ASSEMBLY
[C200]
REAR FINAL DRIVE ASSEMBLY PFP:38300
REMOVAL
1. Remove rear propeller shaft. Refer to PR-3, "REAR PROPELLER SHAFT" .
2. Remove drain plug to drain oil.
3. Remove rear axle shaft.
4. Remove air breather hose.
5. Set a transmission jack, and remove final drive mounting nuts. Then remove final drive assembly.
INSTALLATION
Install in reverse order of removal.
CAUTION:
Install gasket in the correct direction shown in the figure.
After installing, bleed air in brake, adjust parking brake, and
fill oil to final drive.
SDIA0504E
RFD-8
REAR FINAL DRIVE ASSEMBLY
[C200]
Disassembled Drawing EDS000GS
RFD
SDIA0425E
RFD-9
REAR FINAL DRIVE ASSEMBLY
[C200]
Inspection before Disassembly EDS000GT
SDIA0304J
TOTAL PRELOAD
Rotate companion flange several times. Using preload gauge,
measure preload.
Total preload :
1.4 - 2.8 Nm (0.14 - 0.29 kg-m,13-25in-lb)
SPD241
SDIA0306J
SDIA0307J
TOOTH CONTACT
Check tooth contact. Refer to RFD-20, "Tooth Contact" .
RFD-10
REAR FINAL DRIVE ASSEMBLY
[C200]
Disassembly and Assembly EDS000GU
RFD
SDIA0311E
SDIA0312J
H
SPD204
L
SDIA0022E
RFD-11
REAR FINAL DRIVE ASSEMBLY
[C200]
3. Using a brass rod, tap bearing outer race evenly to remove.
4. For front, drive out bearing with oil seal.
SDIA0023E
SDIA0024J
SDIA0318E
RFD-12
REAR FINAL DRIVE ASSEMBLY
[C200]
Turn differential gear case upside down, and check side gear
back clearance on other side as well. A
SDIA0319J
RFD
3. Disassembly
Confirm mating marks.
CAUTION:
When making mating marks, use paint to avoid scratch- F
ing differential gear case.
G
SDIA0321E
SDIA0322E
K
SDIA0323E
RFD-13
REAR FINAL DRIVE ASSEMBLY
[C200]
Follow Parts inspection, check the following parts, and take
action against it: side gear, side gear thrust washer, pinion
mating shaft, pinion mating gear, pinion, pinion mating thrust
washer, thrust block, and differential gear case.
SDIA0324J
PARTS INSPECTION
Item Corrective action
If tooth contact is unusual, determine the possible cause. When assembling, adjust tooth contact
Drive gear properly. If gear is worn out excessively, or cannot be adjusted properly, replace it as a set.
Drive pinion If cracks, damage, and seizure is detected on tooth face, replace it as a set.
If tooth damage is light, repair it using oil stone.
Check for seizure, peeling, wear, and corrosion. Also check for sticking, unusual noise, and
Bearing
roughness while turning bearing. If any, replace it.
SDIA0325J
RFD-14
REAR FINAL DRIVE ASSEMBLY
[C200]
2. Assemble side gear to differential gear case.
3. Then, assemble pinion mating assembly (pinion mating shaft A
assembled with pinion mating gear and thrust washer).
SDIA0326J
RFD
4. Assemble side gear and thrust washer to the other side.
CAUTION:
When assembling, use the original thrust washer removed E
during assembly, or the one of same size.
G
SDIA0327J
SPD656
RFD-15
REAR FINAL DRIVE ASSEMBLY
[C200]
9. Assemble the selected thrust washer with side gear, and assem-
ble pinion mating assembly.
CAUTION:
Apply gear oil to sliding parts on gear and washer.
SDIA0326J
SDIA0330J
11. Assemble selected thrust washer and side gear on the other
side.
SDIA0327J
SDIA0332E
RFD-16
REAR FINAL DRIVE ASSEMBLY
[C200]
13. Evenly tighten bolts diagonally. Then tighten them to specified
torque. A
SDIA0333J
RFD
14. Apply sealant (Locktite) to drive gear mounting bolts and threads
of drive gear.
E
G
SDIA0336J
15. Align mating marks on drive gear and differential gear case, and H
assemble them.
16. Evenly tighten bolts diagonally. Then tighten them to specified
torque. I
SDIA0337J
K
17. Press-fit side bearing inner cones on differential case with tool.
L
Tool number:
ST33230000
ST33061000 M
S-PD244
RFD-17
REAR FINAL DRIVE ASSEMBLY
[C200]
1. Make sure all parts are clean. Make sure, also, the bearings are
well lubricated with light oil or type DEXRON automatic trans-
mission fluid.
2. Place the differential carrier, with side bearings and bearing
races installed, into the final drive housing.
SPD919
SPD894
SPD986
5. Install the side bearing caps in their correct locations and torque
the bearing cap retaining bolts.
Specification:
88 - 98 N-m (9.0 - 10.0 kg-m, 65 - 72 ft-lb)
6. Turn the carrier several times to seat the bearings.
SPD526
7. Measure the turning torque of the carrier at the ring gear retain-
ing bolts with a spring gauge, J8129.
Specification:
34.3 -39.2 N (3.5 - 4.0 kg, 7.7 -8.8 lb) of pulling
force at the ring gear bolt
SPD194A
RFD-18
REAR FINAL DRIVE ASSEMBLY
[C200]
8. If the turning torque is not within the specifications, correct the
torque as follows: A
If the turning torque is less than the specified range, install
washers of greater thickness.
If the turning torque is greater than the specification, install thin- B
ner washers to side bearing.
Side bearing adjustment:
C
Refer to RFD-17, "ADJUSTMENT SIDE BEARING
PRELOAD"
SPD772
9. Record the total amount of washer thickness required for the RFD
correct carrier side bearing preload.
10. Remove the carrier from the final drive housing. Save the
selected preload washers for later use during the assembly of E
the final drive unit.
S-PD344
H
ADJUSTMENT DRIVE PINION
Drive Pinion Height
1. First prepared Tools for pinion height adjustment.
I
1. Dummy shaft (KV38103910)
2. Height Gauge (KV38100120)
3. Stopper (KV38100140) J
4. Feeler gauge
2. To simplify the job, make a chart, like the one below, to organize
your calculations. K
LETTER HUNDREDTHS OF A MILLIMETER
H: Head number SPD233
L
N: Measuring clearance
SPD542
RFD-19
REAR FINAL DRIVE ASSEMBLY
[C200]
4. Set Tool (Dummy shaft) as shown t left and tighten drive pinion
nut carefully to correct preload of 1.0 to 1.3 N-m (0.1 to 0.13 kg-
m, 8.7 to 11.3 in-lb).
Tool number: KV38103910
SPD756
SDIA0507E
7. Select the proper washer. Refer to RFD-26, "SERVICE DATA AND SPECIFICATIONS (SDS)" .
If you cannot find the desired thickness of washer, use washer with thickness closest to the calculated
value.
Example:
Calculated value: T = 3.22 mm
Used washer: T = 3.21 mm
Tooth Contact
Checking gear tooth contact pattern is necessary to verify correct relationship between ring gear and drive pin-
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.
RFD-20
REAR FINAL DRIVE ASSEMBLY
[C200]
1. Thoroughly clean ring gear and drive pinion teeth.
2. Sparingly apply a mixture of powdered ferric oxide and oil or A
equivalent to 3 or 4 teeth of ring gear drive side.
SPD199
RFD
3. Hold companion flange steady and rotate the ring gear in both
directions.
E
G
SPD200
SPD007-B
RFD-21
REAR FINAL DRIVE ASSEMBLY
[C200]
ASSEMBLY DIFFERENTIAL CARRIER
1. Press-fit front and rear bearing outer races with Tools.
Tool numbers:
A ST30611000
B ST30621000
C ST30613000
SPD679
SPD377
SPD581
RFD-22
REAR FINAL DRIVE ASSEMBLY
[C200]
5. Apply multi-purpose grease to cavity at sealing lips of oil seal.
Install front oil seal. A
Tool number: KV38100500
SPD557
RFD
6. Place drive pinion bearing spacer, drive pinion bearing adjusting
washer and drive pinion in gear carrier.
E
G
SPD222
SPD708
K
8. Tighten pinion nut to 127 N-m (13 kg-m, 94 ft-lb).
The threaded portion of drive pinion and pinion nut should be
free from oil or grease. L
SPD204
9. 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.
Pinion bearing preload:
1.1 - 1.7 N-m (0.11 - 0.17 kg-m, 9.5 - 14.8 in-lb)
This procedure will have to be repeated if:
Maximum preload is achieved before the minimum pinion nut
torque is reached.
SPD241
RFD-23
REAR FINAL DRIVE ASSEMBLY
[C200]
Minimum preload is not achieved before maximum pinion ut torque is reached.
SPD203
12. Insert left and right side bearing adjusting washers in place
between side bearing and carrier.
SPD558
SPD709
14. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.
SPD226
RFD-24
REAR FINAL DRIVE ASSEMBLY
[C200]
15. Measure ring gear-to-drive pinion backlash with a dial indicator.
Ring gear-to-pinion backlash: A
0.13 - 0.18 mm (0.0051 - 0.0071 in)
If backlash is too small, decrease thickness of right shim and B
increase thickness of left shim by the same amount.
If backlash is too great, reverse the above procedure.
Never change the total amount of shims as it will change the C
bearing preload.
SPD196
RFD
16. Check total preload with Tool.
When checking preload, turn drive pinion in both directions sev-
eral times to seat bearing rollers correctly.
E
Total preload:
1.4 - 2.8 N-m (0.14 - 0.29 kg-m, 13 - 25 in-lb)
F
G
SPD241
RFD-25
SERVICE DATA AND SPECIFICATIONS (SDS)
[C200]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
Side gear backlash (Clearance between side gear and differential case) mm (in) Less than 0.15 (0.0020)
Thickness mm (in) Part number*
0.75 (0.0295) 38424-N3110
0.78 (0.0307) 38424-N3111
Available side gear thrust washers 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
* Always check with the Parts Department for the latest parts information.
Differential carrier assembly turning resistance N (kg, lb) 34.3 - 39.2 (3.5 - 4.0, 7.7 - 8.8)
Thickness mm (in) Part number*
2.00 (0.0787) 38453-N3100
2.05 (0.0807) 38453-N3101
2.10 (0.0827) 38453-N3102
2.15 (0.0846) 38453-N3103
2.20 (0.0866) 38453-N3104
Available side bearing adjusting wash- 2.25 (0.0886) 38453-N3105
ers 2.30 (0.0906) 38453-N3106
2.35 (0.0925) 38453-N3107
2.40 (0.0945) 38453-N3108
2.45 (0.0965) 38453-N3109
2.50 (0.0984) 38453-N3110
2.55 (0.1004) 38453-N3111
2.60 (0.1024) 38453-N3112
* Always check with the Parts Department for the latest parts information.
Total preload N-m (kg-m, in-lb) 1.4 - 2.8 (0.14 - 0.29, 13 - 25)
Ring gear-to-pinion backlash mm (in) 0.13 - 0.18 (0.0051 - 0.0071)
RFD-26
SERVICE DATA AND SPECIFICATIONS (SDS)
[C200]
Drive Pinion Height Adjustment EDS000H0
A
Thickness mm (in) Part number*
3.09 (0.1217) 38154-P6017
3.12 (0.1228) 38154-P6018
B
3.15 (0.1240) 38154-P6019
3.18 (0.1252) 38154-P6020
3.21 (0.1264) 38154-P6021
3.24 (0.1276) 38154-P6022 C
3.27 (0.1287) 38154-P6023
3.30 (0.1299) 38154-P6024
Available pinion height adjusting 3.33 (0.1311) 38154-P6025
washers 3.36 (0.1323) 38154-P6026 RFD
3.39 (0.1335) 38154-P6027
3.42 (0.1346) 38154-P6028
3.45 (0.1358) 38154-P6029
3.48 (0.1370) 38154-P6030 E
3.51 (0.1382) 38154-P6031
3.54 (0.1394) 38154-P6032
3.57 (0.1406) 38154-P6033
3.60 (0.1417) 38154-P6034 F
3.63 (0.1429) 38154-P6035
3.66 (0.1441) 38154-P6036
* Always check with the Parts Department for the latest parts information. G
RFD-27
PRECAUTIONS
[H233B]
PRECAUTIONS
[H233B] PFP:00001
Caution EDS000G5
Before starting diagnosis of vehicle, understand trouble symptoms well. Perform correct and systematic
operations.
Check for the correct installation status prior to removal or disassembly. When mating marks are required,
be sure they do not interfere with the function of the parts they are applied to.
Perform overhaul in clean place. Using a dustproof room is recommended.
Before disassembly, using steam or white gasoline, etc., completely remove sand and mud from exterior
of unit, and prevent them from entering into unit during disassembly or assembly.
Check appearance of disassembled parts for damage, deformation, and unusual wear. If a malfunction is
detected, replace it with a new one.
As a rule, replace lock pins, oil seals, and bearings with new ones every time they are removed.
Use Nissan Genuine Parts for replacement.
In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
Clean and flush the parts sufficiently, and blow them dry.
Be careful not to damage sliding surfaces and mating surfaces.
When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.
Always use shop paper for cleaning the inside of components.
Do not use cotton gloves or a shop cloth. Using them may leave lint on the surface of the parts.
During assembly, observe the specified tightening torque, and apply new deferential oil, Vaseline, or multi-
purpose grease as specified for each vehicle, when necessary.
Do not reuse drained oil. Discard waste oil after oil changes or treating part in accordance with local laws
and regulations.
RFD-28
PREPARATION
[H233B]
PREPARATION PFP:00002
A
Special Service Tools EDS000GB
Tool name
Description
Tool number B
Differential attachment C
ST06340000
Mounting final drive
RFD
NT140
E
Differential side bearing adjusting
Adjusting side bearing preload and backlash
nut wrench
(ring gear-drive pinion)
ST32580000
F
NT141
NT431
NT090
RFD-29
PREPARATION
[H233B]
Tool name
Description
Tool number
Drift
ST30621000 Installing pinion rear bearing outer race
a: 79 mm (3.11 in) dia. (Use with ST30611000)
b: 59 mm (2.32 in) dia.
NT073
Drift
ST30613000 Installing pinion front bearing outer race
a: 72 mm (2.83 in) dia. (Use with ST30611000)
b: 48 mm (1.89 in) dia.
NT073
NT115
RFD-30
NVH Troubleshooting Chart
: Applicable
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page
Inproper gear contact Refer toRFD-49
Tooth surfaces worn Refer to RFD-42RFD-39
Incorrect baklash Refer toRFD-35
Companion flange excessive runout
Improper gear oil Refer to MA section.
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU sections.
[H233B]
PFP:00003
BRAKES NVH in BR section.
EDS000G4
STEERING NVH in PS section.
RFD
M
G
H
C
K
A
F
L
I
FRONT OIL SEAL
[H233B]
FRONT OIL SEAL PFP:38189
REMOVAL
1. Remove Propeller Shaft.
2. Put a mark on the end of the drive pinion corresponding to the B
position mark on the final drive companion flange.
CAUTION:
When making mating marks, use paint, etc., to avoid
scratching on surface.
SDIA0270E
SPD738
INSTALLATION
1. Apply multi-purpose grease to oil seal lips. Using a drift (special
service tool) as shown, install oil seal. It should become flush
with case end surface.
Tool number :KV38100500
CAUTION:
When installing, be careful not to incline oil seal.
Discard old oil seal; replace with a new one.
SPD739
SDIA0270E
RFD-32
REAR FINAL DRIVE ASSEMBLY
[H233B]
REAR FINAL DRIVE ASSEMBLY PFP:38300
A
Removal and Installation EDS000G7
REMOVAL
1. Remove rear of propeller shaft.
B
Plug front end of transfer.
2. Remove drain plug to drain oil.
3. Remove axle shaft.
C
Refer to RAX-7, "Removal and Installation"
4. Remove rear final drive mounting bolts.
CAUTION: RFD
Be careful not to damage spline, sleeve yoke and front oil seal when removing propeller shaft.
INSTALLATION
Fill final drive with recommended gear oil. E
SPD123 H
SPD767
RFD-33
REAR FINAL DRIVE ASSEMBLY
[H233B]
Disassembled Drawing EDS000GK
SDIA0505E
RFD-34
REAR FINAL DRIVE ASSEMBLY
[H233B]
Inspection before Disassembly EDS000G8
A
Before disassembling final drive, perform the following inspection.
TOTAL PRELOAD
1. Turn drive pinion in both directions several times to seat bearing B
rollers correctly.
2. Check total preload with Tool.
Total preload: C
SPD149 E
RING GEAR TO DRIVE PINION BACKLASH
Check backlash of ring gear with a dial indicator at several
points. F
Ring gear to drive pinion backlash:
0.13 - 0.18mm (0.0051 - 0.0071 in) G
SPD246
I
RING GEAR RUNOUT
Check runout of ring gear with a dial indicator.
Runout limit: J
0.08mm (0.0031 in)
SPD247
TOOTH CONTACT M
Check tooth contact. Refer to RFD-49, "Tooth Contact"
Disassembly and Assembly EDS000G9
SPD683
RFD-35
REAR FINAL DRIVE ASSEMBLY
[H233B]
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.
Bearing caps are line-bored during manufacture and should
be put back in their original places.
SPD249
SPD250
SPD684
SPD685
RFD-36
REAR FINAL DRIVE ASSEMBLY
[H233B]
Be careful to keep the side bearing outer races together with
their respective inner cones - do not mix them up. A
SPD011
RFD
REMOVE DRIVE PINION GEAR ASSEMBLY
1. Remove drive pinion nut with tool.
2. Remove companion flange with puller. E
G
SPD480A
3. Take out drive pinion together with pinion rear bearing inner H
cone, drive pinion bearing spacer and pinion bearing adjusting
shim.
I
SPD687 K
4. Remove front oil seal and pinion front bearing inner cone.
5. Remove pinion bearing outer races with a brass drift. L
SPD563
RFD-37
REAR FINAL DRIVE ASSEMBLY
[H233B]
6. Remove pinion rear bearing inner cone and drive pinion adjust-
ing washer.
Tool number: ST30031000
SPD018
Tool number:
A ST33051001
B ST33061000
SPD207A
SPD022
SPD024
RFD-38
REAR FINAL DRIVE ASSEMBLY
[H233B]
4. Drive out pinion mate shaft lock pin, with punch from ring gear
side. A
Lock pin is calked at pin hole mouth on differential case.
SPD025
RFD
Follow Parts Inspection, check the following parts, and take
action against it: side gear, side gear thrust washer, pinion
mating shaft, pinion mating gear, pinion, pinion mating thrust E
washer, thrust block, and differential gear case.
G
SPD584
SPD552
RFD-39
REAR FINAL DRIVE ASSEMBLY
[H233B]
2. Fit pinion mate shaft to differential case so that it meets lock pin
holes.
3. Adjust backlash between side gear and pinion mate gear by
selecting side gear thrust washer.
Refer to RFD-54, "SERVICE DATA AND SPECIFICATIONS
(SDS)"
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and dif-
ferential case):
SPD258
0.10 - 0.20 mm (0.0039 - 0.0079 in)
4. Install pinion mate shaft lock pin with a punch.
Make sure lock pin is flush with case.
SPD030
5. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see they turn properly.
6. Install differential case assembly on ring gear.
Tighten bolts in a criss-cross pattern, lightly tapping bolt head
with a hammer.
SPD322
S-PD244
RFD-40
REAR FINAL DRIVE ASSEMBLY
[H233B]
DISASSEMBLY DIFFERENTIAL CASE (LIMITED SLIP DIFFERENTIAL)
A
RFD
SDIA0506E I
CAUTION:
Do not run engine when one wheel (rear) is off the ground.
1. Measure differential torque with Tool. J
If it is not within the specifications, inspect components of limited
slip differential.
Differential torqu: K
88 - 108 N-m (9 - 11 kg-m, 65 - 80 ft-lb)
Tool number: A KV38105210 L
Tool number: B KV38105220
SPD415 M
SPD275
RFD-41
REAR FINAL DRIVE ASSEMBLY
[H233B]
5. Remove couple bolts on differential cases A and B with a press.
Tool number: ST33081000
6. Separate differential case A and B.
Draw out component parts (discs and plates, etc.).
Put marks on gears and pressure rings so that they can be
reinstalled in their original positions from which they were
removed.
Clean the disassembled parts in suitable solvent and blow dry
with compressed air.
SPD363A
SPD359A
RFD-42
REAR FINAL DRIVE ASSEMBLY
[H233B]
3. To test if friction disc or plate is not distorted, place it on a spur-
face plate and rotate it by hand with indicating finger of dial A
gauge resting against disc or plate surface.
Allowable warpage:
0.08 mm (0.0031 in) B
SPD279
RFD
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. E
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. F
Wear limit:
0.1mm (0.004 in) or less
A B = Wear limit mm (in) G
Measuring points
A: Projected portion
B: Frictional surface H
SPD381A
K
ADJUSTMENT DIFFERENTIAL CASE (LIMITED SLIP DIFFERENTIAL)
Friction Disc and Friction Plate End Play
End play of friction disc and friction plate can be calculated by L
using following equation and should be adjusted within following
range.
Adjustment can be made by selecting friction disc having two M
different thicknesses.
End play E:
0.05 - 0.15 mm (0.0020 - 0.0059 in)
E = A (B + C)
A: Length of differential case contact surface to differential case
SPD383A
inner bottom.
RFD-43
REAR FINAL DRIVE ASSEMBLY
[H233B]
B: Total thickness of friction discs, friction plates, spring disc and
spring plate in differential case on one side.
C: Length of differential case contact surface to back side of side
gear.
1. Measure values of A.
Standard length A:
49.50 - 49.55 mm (1.9488 - 1.9508 in)
SPD417
SPD420
3. Measure values of C.
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.
Then adjust the dial indicator scale to zero with its tip on the
master gauge.
SPD418
c. Install pinion mate gears, side gears and pinion mate shaft in dif-
ferential case B.
d. Set dial indicator's tip on the side gear, and read the indication.
Example:
E = A - D = A - (B + C) = 0.05 to 0.15 mm
A = 49.52 mm
B = 19.45 mm
C = 29.7 mm
D =B +C SPD419
RFD-44
REAR FINAL DRIVE ASSEMBLY
[H233B]
ASSEMBLY DIFFERENTIAL CASE (LIMITED SLIP DIFFERENTIAL)
Prior to assembling discs and plates, properly lubricate them by A
dipping them in limited slip differential oil.
1. Alternately position specified number of friction plates and fric-
tion discs on rear of side gear. B
Always position a friction plate first on rear of side gear.
SPD421 RFD
SPD384A
H
3. Install friction plate guides.
Correctly align the raised portions of friction plates, and apply
grease to inner surfaces of friction plate guides to prevent I
them from falling.
K
SPD385A
4. Install differential case B over side gear, discs, plates and fric- L
tion plate guide assembly.
Install differential case B while supporting friction plate guides
with your middle finger inserted through oil hole in differential M
case.
Be careful not to detach spring disc from the hexagonal part of
the side gear.
SPD386A
RFD-45
REAR FINAL DRIVE ASSEMBLY
[H233B]
5. Install pinion mate gears and pinion mate thrust washers on pin-
ion mate shaft, then install pinion mate shaft in differential case
B.
SPD426
SPD387A
SPD388A
SPD364A
RFD-46
REAR FINAL DRIVE ASSEMBLY
[H233B]
12. Press-fit side bearing inner cones on differential case with Tool.
A
Tool number:
A ST33190000
B ST33081000 B
S-PD244
RFD
ADJUSTMENT DRIVE PINION
To avoid confusion while calculating bearing shims, it is absolutely necessary to stay with the metric sys-
tem. If you measure anything in inches, the results must be converted to the metric system.
E
Drive Pinion Height
1. First prepare Tools for pinion height adjustment.
1. Height Gauge (ST31251000) F
2. Dummy Shaft (ST31181001)
3. Spacer [thickness: 2.50 mm (0.0984 in)]
4. Feeler Gauge G
2. To simplify the job, make a chart, like the one below, to organize
your calculations.
H
LETTERS HUNDREDTHS OF A MILLIMETER
H: Head number SPD758
M
SPD542
SPD759
RFD-47
REAR FINAL DRIVE ASSEMBLY
[H233B]
S: Figure marked on height gauge
SPD760
4. Place pinion rear bearing inner race and Tools on gear carrier.
SPD271
SPD365A
6. Substitute these values into the equation to calculate the thickness of the washer.
RFD-48
REAR FINAL DRIVE ASSEMBLY
[H233B]
If values signifying H, D and S are not given, regard them as zero and calculate.
A
RFD
SPD541A I
7. Select the proper pinion height washer.
Drive pinion height adjusting washer:
J
Refer to RFD-54, "SERVICE DATA AND SPECI-
FICATIONS (SDS)"
If you cannot find the desired thickness of washer, use washer with thickness closest to the calculated K
value.
Example:
L
Calculated value T = 3.32 mm
Used washer T = 3.33 mm
Tooth Contact M
Gear tooth contact pattern check is necessary to verify correct relationship between ring gear and drive
pinion.
Hypoid gear sets which are not positioned properly in relation to one another may be noisy, or have short
life or both. With a pattern check, the most desirable contact for low noise level and long life can be
assured.
1. Thoroughly clean ring gear and drive pinion teeth.
2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.
SPD005
RFD-49
REAR FINAL DRIVE ASSEMBLY
[H233B]
3. Hold companion flange steady by hand and rotate the ring gear
in both directions.
SPD695
SPD007-B
SPD580
RFD-50
REAR FINAL DRIVE ASSEMBLY
[H233B]
2. Select drive pinion height adjusting washer. Refer to
3. Install drive pinion adjusting washer in drive pinion, and press fit A
pinion rear bearing inner cone in it, with press and Tool.
Tool number:
B
ST30901000
SPD377
RFD
4. Place pinion front bearing inner cone in gear carrier.
G
SPD581
SPD291A
K
6. Install drive pinion bearing spacer, pinion bearing adjusting shim
and drive pinion in gear carrier.
L
SPD935-A
SPD697
RFD-51
REAR FINAL DRIVE ASSEMBLY
[H233B]
8. Tighten pinion nut to the specified torque.
The threaded portion of drive pinion and pinion nut should be
free from oil or grease.
SPD481A
SPD684
12. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.
Do not tighten at this point to allow further tightening of side
bearing adjusters.
SPD265
RFD-52
REAR FINAL DRIVE ASSEMBLY
[H233B]
13. Tighten both right and left side bearing adjusters alternately and
measure ring gear backlash and total preload at the same time. A
Adjust right and left side bearing adjusters by tightening them
alternately so that proper ring gear backlash and total preload
can be obtained.
B
Ring gear-to-drive pinion backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in)
C
SPD246
RFD
When checking preload, turn drive pinion in both directions sev-
eral times to set bearing rollers.
Tool number: ST3127S000 E
Total preload:
P1 + [0.3 - 0.4 N-m (0.03 - 0.04 kg-m, 2.6 - 3.5 in-lb)]
P1 : Drive pinion preload F
G
SPD149
SPD698
K
16. Check runout of ring gear with a dial indicator.
Runout limit: 0.08 mm (0.0031 in) L
If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the ring
gear and the differential case. M
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.
17. Check tooth contact. Refer to RFD-49, "Tooth Contact"
SPD247
RFD-53
SERVICE DATA AND SPECIFICATIONS (SDS)
[H233B]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
Stnderd Optional
Rear final drive 2-pinion LSD
Gear retio 4.875 4.900
Number of teeth (Ring gear/drive pinion) 39/8 49/10
Oil capacity(Approx.) (Imp) 2.8(4-7/8)
Side gear backlash (Clearance bettween side gear and differential case) mm(in) 0.10-0.020(0.0039-0.0079)
Thickness mm(in) Part number
Available side gear thrust washers 1.75(0.0689) 38424-T5000
1.80(0.0709) 38424-T5001
1.85(0.0728) 38424-T5002
*:Always check with the Parts Department for the latest parts information.
RFD-54
SERVICE DATA AND SPECIFICATIONS (SDS)
[H233B]
DRIVE PINION HEIGHT ADJUSTMENT
Thickness mm (in) Part number*
A
2.58(0.1016) 38151-01J00
2.61(0.1028) 38151-01J01
2.64(0.1039) 38151-01J02 B
2.67(0.1051) 38151-01J03
2.70(0.1063) 38151-01J04
2.73(0.1075) 38151-01J05
2.76(0.1087) 38151-01J06 C
2.79(0.1098) 38151-01J07
2.82(0.1110) 38151-01J08
2.85(0.1122) 38151-01J09
RFD
2.88(0.1134) 38151-01J10
2.91(0.1146) 38151-01J11
2.94(0.1157) 38151-01J12
2.97(0.1169) 38151-01J13 E
3.00(0.1181) 38151-01J14
3.03(0.1193) 38151-01J15
3.06(0.1205) 38151-01J16
Available pinion height 3.09(0.1217) 38151-01J17 F
adjust washers 3.12(0.1228) 38151-01J18
3.15(0.1240) 38151-01J19
3.18(0.1252) 38151-01J60
3.21(0.1264) 38151-01J61 G
3.24(0.1276) 38151-01J62
3.27(0.1287) 38151-01J63
3.30(0.1299) 38151-01J64
3.33(0.1311) 38151-01J65
H
3.36(0.1323) 38151-01J66
3.39(0.1335) 38151-01J67
3.42(0.1346) 38151-01J68
I
3.45(0.1358) 38151-01J69
3.48(0.1370) 38151-01J70
3.51(0.1382) 38151-01J71
3.54(0.1394) 38151-01J72 J
3.57(0.1406) 38151-01J73
3.60(0.1417) 38151-01J74
3.63(0.1429) 38151-01J75
3.66(0.1441) 38151-01J76 K
*:Always check with the Parts Department for the latest parts information.
RFD-55
SERVICE DATA AND SPECIFICATIONS (SDS)
[H233B]
DRIVE PINION PRELOAD ADJUSTMENT
Drive pinion bearing preload adjusting method Adjusting shim and spacer
Drive pinion preload without front oil seal Nm (kg-cm,in-lb) [P1] 1.2-2.0(12-20,10-17)
Thickness mm (in) Part number*
2.31(0.0909) 38125-82100
2.33(0.0917) 38126-82100
2.35(0.0925) 38127-82100
2.37(0.0933) 38128-82100
Available front 2.39(0.0941) 38129-82100
drive pinion 2.41(0.0949) 38130-82100
bearing adjusting 2.43(0.0957) 38131-82100
shims 2.45(0.0965) 38132-82100
2.47(0.0972) 38133-82100
2.49(0.0980) 38134-82100
2.51(0.0988) 38135-82100
2.53(0.0996) 38136-82100
2.55(0.1004) 38137-82100
2.57(0.1012) 38138-82100
2.59(0.1020) 38139-82100
Thickness mm (in) Part number*
Available 4.50(0.1772) 38165-76000
drive pinion 4.75(0.1870) 38166-76000
bearing adjusting 5.00(0.1969) 38167-76000
spacers 5.25(0.2067) 38166-01J00
5.50(0.2165) 38166-01J10
*:Always check with the Parts Department for the latest parts information.
RFD-56