PROPELLER SHAFT &DIFFERENTIAL CARRIERSECTION PDCONTENTSPREPARATION................................................................3Special Service Tools ..................................................3NOISE, VIBRATION AND HARSHNESS (NVH)TROUBLESHOOTING.....................................................7NVH Troubleshooting Chart.........................................7PROPELLER SHAFTPROPELLER SHAFT ......................................................8On-vehicle Service.....................................................10Removal and Installation............................................10Inspection...................................................................10Disassembly............................................................... 11Assembly ...................................................................12FINAL DRIVEON-VEHICLE SERVICE ................................................14Front Oil Seal Replacement(Front final drive: Model R180A) ...............................14Rear Cover Gasket Replacement(Rear final drive: Model C200) ..................................14REMOVAL AND INSTALLATION (Front finaldrive)..............................................................................15Removal .....................................................................15Installation..................................................................15REMOVAL AND INSTALLATION (Rear final drive) ....16Removal .....................................................................16Installation..................................................................16R180AFRONT FINAL DRIVE...................................................17DISASSEMBLY..............................................................18Pre-inspection............................................................18Final Drive Housing ...................................................18Differential Case ........................................................20Extension Tube and Differential Side Shaft ..............21INSPECTION..................................................................23Ring Gear and Drive Pinion ......................................23Differential Case Assembly........................................23Bearing.......................................................................23ADJUSTMENT...............................................................24Side Bearing Preload.................................................24Pinion Gear Height and Pinion Bearing Preload.......25Tooth Contact.............................................................29ASSEMBLY....................................................................30Extension Tube and Differential Side Shaft ..............30Differential Case ........................................................30Final Drive Housing ...................................................31H190AREAR FINAL DRIVE .....................................................35DISASSEMBLY..............................................................36Pre-inspection............................................................36Differential Carrier......................................................36Differential Case ........................................................38INSPECTION..................................................................40Ring Gear and Drive Pinion ......................................40Differential Case Assembly........................................40Bearing.......................................................................40ADJUSTMENT...............................................................41Side Bearing Preload.................................................41Pinion Gear Height ....................................................42Tooth Contact.............................................................46ASSEMBLY....................................................................47Differential Case ........................................................47Differential Carrier......................................................48C200REAR FINAL DRIVE .....................................................522WD models .....................................................52GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDX4WD models .....................................................53DISASSEMBLY..............................................................54Pre-inspection............................................................54Differential Carrier......................................................54Differential Case ........................................................56INSPECTION..................................................................58Ring Gear and Drive Pinion ......................................58Differential Case Assembly........................................58Bearing.......................................................................58ADJUSTMENT...............................................................59Side Bearing Preload..................................................59Pinion Gear Height ....................................................60Tooth Contact.............................................................64ASSEMBLY....................................................................65Differential Case ........................................................65Differential Carrier......................................................66SERVICE DATA AND SPECIFICATIONS (SDS) ..........70Propeller Shaft ...........................................................70Final Drive..................................................................71General Specifications ..........................................71Inspection And Adjustment (R180A) .....................72Inspection And Adjustment (H190A) .....................73Inspection And Adjustment (C200) .......................74CONTENTS(Contd.)PD-2Special Service ToolsThe actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.Tool number(Kent-Moore No.)Tool nameDescriptionUnit applicationR180A H190A C200ST3127S000(See J25765-A)Preload gauge1 GG91030000(J25765)Torque wrench2 HT62940000( )Socket adapter3 HT62900000( )Socket adapterNT124Measuring pinion bearing preloadand total preloadX X XKV38100800(J25604-01), (J34310)Differential attachmentNT119Mounting final drive(To use, make a new hole.)X a: 152 mm (5.98 in)ST06310000(J25602-01)Differential attachmentNT140Mounting final drive X ST33290001(J25810-A)Side bearing outer racepullerNT076Removing side bearing outer raceand side oil sealX ST38060002(J34311)Drive pinion flangewrenchNT113Removing and installing propellershaft lock nut and drive pinion locknutX X XST3090S000( )Drive pinion rear innerrace puller set1 ST30031000(J22912-01)Puller2 ST30901000(J26010-01)BaseNT527Removing and installing drive pinionrear inner coneX X Xa: 79 mm (3.11 in) dia.b: 45 mm (1.77 in) dia.c: 35 mm (1.38 in) dia.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPREPARATIONPD-3Tool number(Kent-Moore No.)Tool nameDescriptionUnit applicationR180A H190A C200ST3306S001Differential side bearingpuller set1 ST33051001(J22888-20)Body2 ST33061000(J8107-2)AdapterNT072Removing and installing differentialside bearing inner coneX X Xa: 28.5 mm (1.122 in) dia.b: 38 mm (1.50 in) dia.ST33230000(J25805-01)Differential side bearingdriftNT085Installing side bearing inner coneX X Xa: 51 mm (2.01 in) dia.b: 41 mm (1.61 in) dia.c: 28.5 mm (1.122 in) dia.ST33081000( )Side bearing pulleradapterNT431Installing side bearing inner cone Xa: 43 mm (1.69 in) dia.b: 33.5 mm (1.319 in) dia.KV38100600(J25267)Side bearing spacer driftNT528Installing side bearing spacer Xa: 8 mm (0.31 in)b: R42.5 mm (1.673 in)ST30611000(J25742-1)DriftNT090Installing pinion rearbearing outer raceX X XST30621000(J25742-5)DriftNT073Installing pinion rear bearing outerraceX X Xa: 79 mm (3.11 in) dia.b: 59 mm (2.32 in) dia.ST30701000(J25742-2)DriftNT073Installing pinion front bearing outerraceX a: 61.5 mm (2.421 in) dia.b: 41 mm (1.61 in) dia.PREPARATIONSpecial Service Tools (Contd)PD-4Tool number(Kent-Moore No.)Tool nameDescriptionUnit applicationR180A H190A C200ST30613000(J25742-3)DriftNT073Installing pinion front bearing outerrace X Xa: 72 mm (2.83 in) dia.b: 48 mm (1.89 in) dia.KV381025S0( )Oil seal fitting tool1 ST30720000(J25405)Drift bar2 KV38102510( )DriftNT525Installing front oil sealX X a: 77 mm (3.03 in) dia.b: 55 mm (2.17 in) dia.c: 71 mm (2.80 in) dia.d: 65 mm (2.56 in) dia.KV38100500(J25273)Gear carrier front oil sealdriftNT115Installing front oil seal Xa: 85 mm (3.35 in) dia.b: 60 mm (2.36 in) dia.ST33720000(J25817)Differential side retainerguideNT138Installing side retainerX ST33270000(J25809)Side oil seal driftNT526Installing side oil sealX a: 62 mm (2.44 in) dia.b: 28 mm (1.10 in) dia.(J34309)Differential shimselectorNT134Adjusting bearing pre-load and gearheightX X X(J25269-4)Side bearing discs(2 reqd)NT136Selecting pinion height adjustingwasherX XGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPREPARATIONSpecial Service Tools (Contd)PD-5Tool number(Kent-Moore No.)Tool nameDescriptionUnit applicationR180A H190A C200(J25269-18)Side bearing discs(2 reqd)NT135Selecting pinion height adjustingwasher X (J8129)Spring gaugeNT127Measuring carrier turning torqueX X X(J35764)Gear carrier side oil sealdriftNT120Installing side oil sealX KV381051S0( )Rear axle shaft dummy1 KV38105110( )Torque wrench side2 KV38105120( )Vice sideNT142Checking differential torque on lim-ited slip differential X XPREPARATIONSpecial Service Tools (Contd)PD-6NVH Troubleshooting ChartUse the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.Reference pagePD-9,12PD-10PD-10PD-23,40,58PD-29,46,64PD-23,40,58PD-33,50,68RefertoMAsectionRefertoPROPELLERSHAFTinthischartRefertoDIFFERENTIALinthischartNVHinFAsectionNVHinFA,RAsectionNVHinFAsectionNVHinFAsectionNVHinBRsectionNVHinSTsectionPossible cause andSUSPECTED PARTSUnevenrotationtorqueCenterbearingimproperinstalllationExcessivecenterbearingaxialendplayCenterbearingmounting(insulator)cracks,damageordeteriorationExcessivejointangleRotationimbalanceExcessiverunoutRoughgeartoothImpropergearcontactToothsurfaceswornIncorrectbacklashCompanionflangeexcessiverunoutImpropergearoilPROPELLERSHAFTDIFFERENTIALDRIVESHAFTAXLEANDSUSPENSIONTIRESROADWHEELBRAKESSTEERINGSymptomPROPELLERSHAFTNoise X X X X X X X X X X X X X XShake X X X X X X X XVibration X X X X X X X X X X XDIFFERENTIAL Noise X X X X X X X X X X X X XX : ApplicableGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXNOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPD-7Front propeller shaft (Model 2F1310)APD025Rear propeller shaft (Model 2S1310)APD024PROPELLER SHAFTPROPELLER SHAFTPD-8Rear propeller shaft (Model 3S1310)WPD017GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPROPELLER SHAFTPROPELLER SHAFTPD-9SPD728SPD102On-vehicle ServicePROPELLER SHAFT VIBRATIONIf vibration is present at high speed, inspect propeller shaft runoutfirst.1. Raise rear end of vehicle until wheels are clear of the ground.2. Measure propeller shaft runout at several points along propel-ler shaft by rotating final drive companion flange using hands.3. If runout exceeds specifications, disconnect propeller shaft atfinal drivecompanionflange. Rotatecompanionflange180degrees, then reconnect propeller shaft.Runout limit: 0.6 mm (0.024 in)4. Check runout again. If runout stillexceeds the limit, replacepropeller shaft assembly.5. Perform road test.APPEARANCE CHECKINGG Inspect propeller shaft tube surface for dents or cracks andreplace as necessary.G Checkcenter bearingfor noiseor damageandreplaceasnecessary.SPD103Removal and Installation1. Placematchingmarksonflanges, thenseparatepropellershaft from final drive.SPD3592. Remove propeller shaft.G Insert plug into rear oil seal after removing rear propellershaft.SPD106InspectionG Inspect propeller shaft runout. If runout exceedsthelimit,replace propeller shaft assembly.Runout limit: 0.6 mm (0.024 in)PROPELLER SHAFTPROPELLER SHAFTPD-10SPD874GInspect journal axial play.If play exceeds the limit, replace propeller shaft assembly.Journal axial play:0.02 mm (0.0008 in) or lessSPD109DisassemblyCENTER BEARING1. Place matching marks on flanges, then separate 2nd tube from1st tube.SPD1102. Place matching marks on the flange and shaft.SPD170A3. Remove locking nut using Tool.Tool number:ST38060002 (J34311)4. Remove companion flange using puller.SPD1135. Remove center bearing using Tool and press.Tool number: ST30031000 (J22912-01)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPROPELLER SHAFTPROPELLER SHAFTInspection (Contd)PD-11SPD128JOURNALNOTE:1. Place matching marks on propeller shaft and flange or yoke.APD0112. Remove snap ring.SPD7323. Removepushedout journal bearingbylightlytappingyokewith a hammer, taking care not to damage journal and yokehole.SPD1314. Remove bearing at opposite side in above operation.Put marks on disassembled parts so that they can bereinstalled in their original positions.SPD114AssemblyCENTER BEARINGG When installing center bearing, position the F mark on cen-ter bearing toward front of vehicle.G Applyacoat of multi-purposelithiumgreasecontainingmolybdenum disulfide to the end face of the center bearingand both sides of the washer.PROPELLER SHAFTPROPELLER SHAFTDisassembly (Contd)PD-12SPD117GStake the nut. Always use new one.G Align match marks when assembling tubes.SPD133JOURNAL1. Assemble journal bearing. Apply recommended multi-purposegrease on bearing inner surface.When assembling, be careful that needle bearing does not falldown.APD0122. Select snap ring that will provide specified play in axial directionof journal, and install them.Refer to SDS, PD-70.Select snap rings with a difference in thickness at both sideswithin 0.06 mm (0.0024 in).SPD7323. Adjust thrust clearance between bearing and snap ring to zeroby tapping yoke.SPD8744. Check to see that journal moves smoothly and check for axialplay.Axial play: 0.02 mm (0.0008 in) or lessGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPROPELLER SHAFTPROPELLER SHAFTAssembly (Contd)PD-13SPD733Front Oil Seal Replacement(Front final drive: Model R180A)1. Remove front propeller shaft.2. Loosen drive pinion nut.Tool number: ST38060002 (J34311)SPD7343. Remove companion flange using puller.SPD7354. Remove front oil seal.SPD7365. Apply multi-purpose grease to cavity at sealing lips of oil seal.Press front oil seal into carrier.Tool number:ST30720000 (J25405)6. Install companion flange and drive pinion nut.7. Install propeller shaft.SPD740-ARear Cover Gasket Replacement(Rear final drive: Model C200)1. Drain gear oil.2. Remove rear cover and rear cover gasket.3. Install new rear cover gasket and rear cover.4. Fill final drive with recommended gear oil.ON-VEHICLE SERVICEFINAL DRIVEPD-14SPD741Removal1. Remove front propeller shaft.2. Separate drive shaft from front final drive. Refer to FA section[Drive Shaft, FRONT AXLE (4WD)].3. Remove engine mounting bolts and raise up engine.4. Removefront final drivetogether withdifferential mountingmember.SPD742Installation1. Install front final drive assembly together with differentialmounting member.SPD7432. Tighten front final drive securing bolts and nuts by following theprocedure to prevent drive train vibration.a. Temporarily tighten nutA .b. Temporarily tighten nutB .c. Tighten boltC to the torque of 68 to 87 Nm (6.9 to 8.9 kg-m,50 to 64 ft-lb).d. Tighten boltD to the torque of 68 to 87 Nm (6.9 to 8.9 kg-m,50 to 64 ft-lb).e. Tighten nutA to the torque of 68 to 87 Nm (6.9 to 8.9 kg-m,50 to 64 ft-lb).f. Tighten nutB to the torque of 68 to 87 Nm (6.9 to 8.9 kg-m,50 to 64 ft-lb).g. Tighten nutE to the torque of 68 to 87 Nm (6.9 to 8.9 kg-m,50 to 64 ft-lb).3. Install drive shaft. Refer to FA section [Drive Shaft, FRONTAXLE (4WD)].4. Install front propeller shaft.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXREMOVAL AND INSTALLATION (Front final drive)FINAL DRIVEPD-15RemovalGRemove propeller shaft.Plug front end of transfer.GRemove axle shaft.Refer to RA section (REAR AXLE).CAUTION:GBe careful not to damage spline, sleeve yoke and front oilseal when removing propeller shaft.GBeforeremovingthefinal driveassemblyor rear axleassembly, disconnect the ABS sensor harness connectorfrom the assembly and move it away from the final drive/rear axle assembly area. Failure to do so may result in thesensor wiresbeingdamagedandthesensor becominginoperative.SPD123InstallationGFill final drive with recommended gear oil.REMOVAL AND INSTALLATION (Rear final drive)FINAL DRIVEPD-16APD026GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXFRONT FINAL DRIVER180APD-17SPD634Pre-inspectionBefore disassembling final drive, perform the following inspection.G Total preloada. Turn drive pinion in both directions several times to set bearingrollers.b. Check total preload with Tool.Tool number: ST3127S000 (J25765-A)Total preload:1.2 - 2.3 Nm(12 - 23 kg-cm, 10 - 20 in-lb)SPD635GRing gear-to-drive pinion backlashCheckbacklashof ringgearwithadial indicatorat severalpoints.Ring gear-to-drive pinion backlash:0.13 - 0.18 mm (0.0051 - 0.0071 in)SPD636GRing gear runoutCheck runout of ring gear with a dial indicator.Runout limit:0.05 mm (0.0020 in)G Tooth contactCheck tooth contact. Refer to ADJUSTMENT, PD-29.SPD637Final Drive Housing1. Usingthreespacers [20mm(0.79in)], mount final driveassembly on Tool.Tool number:KV38100800 (J34310), (J25604-01)SPD6382. Remove extension tube and differential side shaft assembly.DISASSEMBLYR180APD-18SPD7133. Remove differential side flange.SPD6394. Mark side retainers for identification. Remove side retainers.Becareful not toconfuseright andleft sideretainersandshims.SPD3095. Extract differential case from final drive housing.PD2436. Remove side outer races.Tool number: ST33290001 (J25810-A)Keep the side bearing outer races together with their respec-tive inner cones do not mix them up.7. Remove side oil seal.SPD171A8. Loosen drive pinion nut.Tool number: ST38060002 (J34311)9. Remove companion flange with puller.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDISASSEMBLYR180AFinal Drive Housing (Contd)PD-19SPD64110. Take out drive pinion together with pinion rear bearing innercone, drive pinion bearing spacer and pinion bearing adjustingwasher.11. Remove front oil seal and pinion front bearing inner cone.PD34912. Remove pinion front and rear bearing outer races with brassdrift.SPD20913. Remove pinion rear bearing inner cone and drive pinionadjusting washer.Tool number: ST30031000 (J22912-01)SPD642Differential Case1. Remove side bearing inner cones.To prevent damage to bearing, engage puller jaws in grooves.Tool numbers:A ST33051001 (J22888-20)B ST33061000 (J8107-2)DISASSEMBLYR180AFinal Drive Housing (Contd)PD-20SPD022Be careful not to confuse the right and left hand parts.SPD0242. Loosen ring gear bolts in a criss-cross fashion.3. Tap ring gear off differential case with a soft hammer.Tap evenly all around to keep ring gear from binding.SPD6434. Separate differential case LH and RH.PutmatchmarksonbothdifferentialcaseLHandRHsidesprior to separating them.SPD644Extension Tube and Differential Side Shaft1. Remove differential side shaft assembly from extension tube.SPD236A2. Cut rear axle bearing collar with cold chisel. Be careful not todamage differential side shaft.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDISASSEMBLYR180ADifferential Case (Contd)PD-21SPD6463. Reinstall differential side shaft into extension tube and securewith bolts. Remove rear axle bearing by drawing out differentialside shaft from rear axle bearing with puller.SPD6474. Remove grease seal.DISASSEMBLYR180AExtension Tube and Differential Side Shaft(Contd)PD-22Ring Gear and Drive PinionCheck gear teeth for scoring, cracking or chipping.If any damaged part is evident, replace ring gear and drive pinionas a set (hypoid gear set).SPD648Differential Case AssemblyCheck mating surfaces of differential case, side gears, pinion mategears, pinion mate shaft and thrust washers.SPD715Bearing1. Thoroughly clean bearing.2. Check bearing for wear, scratches, pitting or flaking.Check tapered roller bearing for smooth rotation. If damaged,replace outer race and inner cone as a set.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXINSPECTIONR180APD-23For quiet and reliable final drive operation, the following fiveadjustments must be made correctly:1. Side bearing preload2. Pinion gear height3. Pinion bearing preload4. Ring gear-to-pinion backlash. Refer to ASSEMBLY, PD-33.5. Ring and pinion gear tooth contact pattern.SPD191ASide Bearing PreloadA selection of carrier side retainer adjusting shims is requiredfor successful completion of this procedure.1. Make sure all parts are clean. Also make sure the bearings arewell lubricatedwithlight oil ortypeDEXRONTM automatictransmission fluid.2. Installdifferentialcarrier and side bearing assembly into thefinal drive housing.SPD192A3. Place all of the original side retainer adjusting shims onto thesidebearingretainer that goesat theringgear endof thecarrier.SPD193A4. Install both bearing retainers onto the final drive housing andtorque the retainer bolts.Bolt torque specification:: 9 - 12 Nm (0.9 - 1.2 kg-m, 78 - 104 in-lb)SPD194A5. Turn the carrier several times to seat the bearings.6. Measure the carrier turning torque with a spring gauge, J8129,at the ring gear retainer bolt.Turning torque specification:34.3 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb)of pulling force at the ring gear boltADJUSTMENTR180APD-247. If the turning torque measured is incorrect, establish the cor-rect bearing preload by adding to or subtracting from the totalamount of shim thickness.G Increaseshimthicknesstodecreaseturningtorqueonthecarrier.G Decreaseshimthicknesstoincreaseturningtorqueonthecarrier.SPD195A8. Record the correct, selected total thickness of the side retaineradjusting shims, and remove the carrier and bearings from thefinal drive housing. Save all shims for later re-use.SPD769Pinion Gear Height and Pinion Bearing Preload1. Make sure all parts are clean and that the bearings are welllubricated.2. Assemblethepiniongear bearingsintothepinionpre-loadshim selector tool, J34309.G Front Pinion Bearing make sure the J34309-3 front pinionbearingseat issecuredtightlyagainst theJ34309-2gaugeanvil. Thenturnthefront pinionbearingpilot, J34309-7, tosecure the bearing in its proper position.SPD196AGRear Pinion Bearing the rear pinion bearing pilot,J34309-8, is used to center the rear pinion bearing only. Therear pinion bearing locking seat, J34309-4, is used to lock thebearing to the assembly.SPD197AGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXADJUSTMENTR180ASide Bearing Preload (Contd)PD-25SPD8933.Placethepinionpreloadshimselector tool gaugescrew,J34309-1, with the pinion rear bearing inner cone installed, intothe final drive housing.SPD199A4.Install the J34309-2 gauge anvil with the front pinion bearinginto the finaldrive housing and assemble it to the J34309-1gauge screw. Make sure that the J34309-16 gauge plate willturn a full 360 degrees, and tighten the two sections by hand.SPD7705.Turn the assembly several times to seat the bearings.SPD234A6.Measure the turning torque at the end of the J34309-2 shaftusing Tool.Tool number: ST3127S000 (J25765-A)Turning torque specification:0.6 - 1.0 Nm (6 - 10 kg-cm, 5.2 - 8.7 in-lb)7.Place the J34309-10 R180A pinion height adapter onto thegauge plate and tighten it by hand.CAUTION:Make sure all machined surfaces are clean.SPD201APINION BEARING PRELOAD WASHER SELECTION8.Place the solid pinion bearing adjusting spacer squarely intothe recessed portion of the J34309-2 gauge anvil.ADJUSTMENTR180APinion Gear Height and Pinion Bearing Preload(Contd)PD-26SPD202A9.Select the correct thickness of pinion bearing preload adjust-ingwasherusingastandardgaugeof 6mm(0.24in)andJ34309-101feelergauge. Theexact total measureyougetwiththegauges is thethickness of theadjustingwasherrequired. Select the correct washer.Drive pinion bearing adjusting washer:Refer to SDS, PD-72.10. Set the selected pinion bearing preload adjusting washer asidefor use when assembling the pinion and bearings into the finaldrive housing.SPD208APINION HEIGHT ADJUSTING WASHER SELECTION11. PlacetheJ34309-10pinionheight adapter ontothegaugeplate and tighten by hand.CAUTION:Make sure all machined surfaces are clean.SPD203A12. Position firmly the side bearing discs, J25269-4, and arbor intothe side bearing bores.SPD204A13. Select thecorrect standardpinionheight adjustingwasherthicknessusingastandardgaugeof 3mm(0.12in) andJ34309-101 feeler gauge. Measure the distance between theJ34309-10 R180A pinion height adapter and the arbor.SPD77114. Write down your exact total measurement.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXADJUSTMENTR180APinion Gear Height and Pinion Bearing Preload(Contd)PD-27SPD54215. Correct the pinion height washer size by referring to the pinionhead number.Therearetwonumberspaintedonthepiniongear.Thefirstone refers to the pinion and ring gear as a matched set andshould be the same as the number on the ring gear. The sec-ond number is the pinion head height number, and it refersto the ideal pinion height from standard for quietest operation.Use the following chart to determine the correct pinion heightwasher.Pinion Head Height NumberAdd or Remove from the StandardPinion Height Washer ThicknessMeasurement6 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)+5 Subtract 0.05 mm (0.0020 in)+6 Subtract 0.06 mm (0.0024 in)16. Select the correct pinion height washer.Drive pinion height adjusting washer:Refer to SDS, PD-72.SPD205A17. Remove the J34309 pinion preload shim selector tool from thefinal drivehousinganddisassembletoretrievethepinionbearings.ADJUSTMENTR180APinion Gear Height and Pinion Bearing Preload(Contd)PD-28Tooth ContactGear toothcontact patterncheckisnecessarytoverifycorrectrelationship between ring gear and drive pinion.Hypoid gear sets which are not positioned properly may be noisy,or have short life, or both. With a pattern check, the most desirablecontact for low noise level and long life can be assured.SPD3571. Thoroughly clean ring gear and drive pinion teeth.2. Sparingly apply a mixture of powdered ferric oxide and oil orequivalent to 3 or 4 teeth of ring gear drive side.SPD6533. Hold companion flange steady and rotate the ring gear in bothdirections.APD018GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXADJUSTMENTR180APD-29SPD206AExtension Tube and Differential Side Shaft1. Measure rear axle bearing end play.Rear axle bearing end play (A - B):0.1 mm (0.0039 in) or lessThe end play can be adjusted with bearing adjusting shim.Available bearing adjusting shims:Refer to SDS, PD-72.SPD6542. Install grease seal.Tool number: (J35764)SPD6553. Install extension tube retainer, rear axle bearing and rear axleshaft bearing collar on differential side shaft.4. Install differential side shaft assembly into extension tube.SPD656Differential Case1. Measure clearance between side gear thrust washer anddifferential case.Clearance between side gear thrust washerand differential case (A - B):Less than 0.15 mm (0.0059 in)The clearance can be adjusted with side gear thrust washer.Available side gear thrust washers:Refer to SDS, PD-72.2. Apply gear oil to gear tooth surfaces and thrust surfaces andcheck to see they turn properly.ASSEMBLYR180APD-30SPD6433. Install differential case LH and RH.SPD7464. Place differential case on ring gear.5. Apply locking agent [Locktite (stud lock) or equivalent] to ringgear bolts, and install them.Tighten bolts in a criss-cross fashion, lightly tapping bolt headwith a hammer.PD3536. Press-fit sidebearinginner conesondifferential casewithTools.Tool numbers:A ST33230000 (J25805-01)B ST33061000 (J8107-2)SPD679Final Drive Housing1. Press-fit front and rear bearing outer races with Tools.Tool numbers:A ST30611000 (J25742-1)B ST30621000 (J25742-5)C ST30701000 (J25742-2)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXASSEMBLYR180ADifferential Case (Contd)PD-31SPD3772. Select pinion bearing adjusting washer and drive pinion bearingspacer. Refer to ADJUSTMENT, PD-25.3. Install drive pinion height adjusting washer in drive pinion, andpress-fit pinion rear bearing inner cone in it, using press andTool.Tool number: ST30901000 (J26010-01)SPD6574. Place pinion front bearing inner cone in final drive housing.5. Apply multi-purpose grease to cavity at sealing lips of oil seal.Install front oil seal.Tool number: ST30720000 (J25405)SPD6586. Placedrivepinionbearingspacer, pinionbearingadjustingwasher and drive pinion in final drive housing.SPD6597. Insert companion flange into drive pinion by tapping thecompanion flange with a soft hammer.PD4668. Tighten pinion nut to the specified torque.The threaded portion of drive pinion and pinion nut should befree from oil or grease.Tool number: ST38060002 (J34311)ASSEMBLYR180AFinal Drive Housing (Contd)PD-32SPD6349. Turndrivepinioninbothdirectionsseveral revolutionsandmeasure pinion bearing preload.Tool number: ST3127S000 (J25765-A)Pinion bearing preload:1.1 - 1.7 Nm (11 - 17 kg-cm, 9.5 - 14.8 in-lb)Whenpinionbearingpreloadisoutsidethespecifications,replacepinionbearingadjustingwasher andspacer withadifferent thickness.SPD33210. Select side retainer adjusting shim.Refer to ADJUSTMENT, PD-24.11. Press-fit side bearing outer race into side retainer.Tool numbers:A ST30611000 (J25742-1)B ST30621000 (J25742-5)SPD66012. Install side oil seal to side retainer.Tool number: ST33270000 (J25809)13. Install differential case assembly.14. Place side retainer adjusting shims (refer to ADJUSTMENT,PD-24), and O-ring on side retainer, and install them in finaldrive housing.Tool number: ST33720000 (J25817)PD420GAlign arrows stamped on side retainer and final drive housing.SPD63515. Measure ring gear-to-drive pinion backlash with a dial indicator.Ring gear-to-drive pinion backlash:0.13 - 0.18 mm (0.0051 - 0.0071 in)G If backlash is too small, decrease thickness of right shim andincrease 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 thebearing preload.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXASSEMBLYR180AFinal Drive Housing (Contd)PD-33SPD63416. Check total preload with Tool.Whencheckingpreload, turndrivepinioninbothdirectionsseveral times to set bearing rollers.Tool number: ST3127S000 (J25765-A)Total preload:1.2 - 2.3 Nm(12 - 23 kg-cm, 10 - 20 in-lb)SPD561GIf preload is too great, add the same amount of shim to eachside.G If preload is too small, remove the same amount of shim fromeach side.Never add or remove a different number of shims for each sideas it will change ring gear-to-drive pinion backlash.17. Recheck ring gear-to-drive pinion backlash because increaseor decrease in thickness of shims willcause change of ringgear to pinion backlash.SPD63618. Check runout of ring gear with a dial indicator.Runout limit:0.05 mm (0.0020 in)G If backlash varies excessively in different places, the variancemay have resulted from foreign matter caught between the ringgear and the differential case.G If the backlash varies greatly when the runout of the ring gearis within a specified range, the hypoid gear set or differentialcase should be replaced.19. Check tooth contact. Refer to ADJUSTMENT, PD-29.20. Install rear cover and gasket.SPD66121. Install extension tube and differential side shaft assembly.ASSEMBLYR180AFinal Drive Housing (Contd)PD-34APD009GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXREAR FINAL DRIVEH190APD-35SPD149Pre-inspectionBefore disassembling final drive, perform the following inspection.G Total preloada. Turn drive pinion in both directions several revolutions to seatbearing rollers correctly.b. Check total preload with Tool.Tool number: ST3127S000 (J25765-A)Total preload:1.2 - 2.2 Nm(12 - 22 kg-cm, 10 - 19 in-lb)SPD140GRing gear-to-drive pinion backlashCheckbacklashof ringgearwithadial indicatorat severalpoints.Ring gear-to-drive pinion backlash:0.13 - 0.18 mm (0.0051 - 0.0071 in)SPD141GRing gear runoutCheck runout of ring gear with a dial indicator.Runout limit:0.08 mm (0.0031 in)SPD004GTooth contactCheck tooth contact. Refer to ADJUSTMENT, PD-46.G Side gear-to-pinion mate gear backlashMeasure clearance between side gear thrust washer anddifferential case with a feeler gauge.Clearance between side gear thrust washer anddifferential case:Less than 0.15 mm (0.0059 in)SPD139Differential Carrier1. Mount differential carrier on Tools.Tool numbers:A ST0501S000 ( )B ST06310000 (J25602-01)DISASSEMBLYH190APD-36SPD0082. Put match marks on one side of side bearing cap with paint orpunch to ensure that it is replaced in proper position duringreassembly.Bearingcapsareline-boredduringmanufactureandshouldbe put back in their original places.SPD0093. Remove side bearing caps.SPD0104. Remove differential case assembly with a pry bar.SPD011Keep the side bearing outer races together with their respectiveinner cones do not mix them up.SPD213A5. Remove drive pinion nut with Tool.Tool number: ST38060002 (J34311)6. Remove companion flange with puller.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDISASSEMBLYH190ADifferential Carrier (Contd)PD-37SPD0157. Remove drive pinion with soft hammer.8. Remove oil seal.SPD5639. Remove pinion bearing outer races with a brass drift.SPD01810. Pull out rear bearing inner cone with a press and Tool.Tool number: ST30031000 (J22912-01)SPD207ADifferential Case1. Remove side bearing inner cones.To prevent damage to bearing, engage puller jaws in groove.Tool numbers:A ST33051001 (J22888-20)B ST33061000 (J8107-2)SPD022Be careful not to confuse the left and right hand parts.DISASSEMBLYH190ADifferential Carrier (Contd)PD-38SPD0242. Spread out lock straps and loosen ring gear bolts in acriss-cross fashion.3. Tap ring gear off differential case with a soft hammer.Tap evenly all around to keep ring gear from binding.SPD0254. Drive out pinion mate shaft lock pin, with Tool from ring gearside.Lock pin is calked at pin hole mouth on differential case.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDISASSEMBLYH190ADifferential Case (Contd)PD-39Ring Gear and Drive PinionCheck gear teeth for scoring, cracking or chipping.If any damaged part is evident, replace ring gear and drive pinionas a set (hypoid gear set).SPD239ADifferential Case AssemblyCheck mating surfaces of differential case, side gears, pinion mategears, pinion mate shaft, and thrust washers.SPD715Bearing1. 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.INSPECTIONH190APD-40For quiet and reliable final drive operation, the following fiveadjustments must be made correctly:1. Side bearing preload2. Pinion gear height3. Pinion bearing preload. Refer to ASSEMBLY, PD-50.4. Ring gear-to-pinion backlash. Refer to ASSEMBLY, PD-50.5. Ring and pinion gear tooth contact patternSide Bearing PreloadA selection of carrier side bearing preload shims is requiredfor successful completion of this procedure.SPD207A1. Make sure all parts are clean and that the bearings are welllubricated with light oil or type DEXRONTM automatictransmission fluid.2. Remove side bearing inner cones.To prevent damage to bearing, engage puller jaws in grooves.Tool numbers:A ST33051001 (J22888-20)B ST33061000 (J8107-2)SPD214A3. Reinstall all of the original side bearing adjusting shims on thecarrier side, away from the ring gear.SPD1454. Reinstall the carrier side bearing using Tools J25805-01 andJ8107-2. Press on the bearings.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXADJUSTMENTH190APD-41SPD215A5. Install carrier and bearings into the final drive housing. Installside bearing caps. Torque the bolts and tap on the caps witha soft hammer to seat the bearings.Side bearing cap bolt torque specification:49 - 59 Nm (5 - 6 kg-m, 36 - 43 ft-lb)SPD194A6. After turningthecarrier several timestoseat thebearings,measure carrier turning force with spring gauge J8129.Turning force specification:34.3 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb)of pulling force at the ring gear boltSPD7767. If necessary, correct the carrier bearing preload by adding toor subtracting from the total amount of shim thickness.Add shim thickness to increase turning force on the carrier.Subtract shimthickness todecreaseturningforceonthecarrier.SPD196APinion Gear Height1. Make sure all parts are clean and that the bearings are welllubricated.2. Assemblethepiniongear bearingsintothepinionpre-loadshim selector Tool, J34309.SPD197AGFront Pinion Bearing make sure the J34309-3 front pinionbearing is secured tightly against the J34309-2 gauge anvil.Then turn the front pinion bearing pilot J34309-5 to secure thebearing in its proper position.G Rear Pinion Bearing the rear pinion bearing pilot, J34309-15, isusedtocentertherearpinionbearingonly. Therearpinion bearing locking seat, J34309-4 is used to lock the bear-ing to the assembly.ADJUSTMENTH190ASide Bearing Preload (Contd)PD-42SPD216A3.Place the pinion pre-load shim selector Tool J34309-1 gaugescrewassembly with the pinion rear bearing inner coneinstalled into the final drive housing.SPD217A4.Assemble the front pinion bearing inner cone and the J34309-2gaugeanvil togetherwiththeJ34309-1gaugescrewinthefinal drivehousing. Makesurethat thepinionheight gaugeplate, J34309-16, will turn a full 360 degrees, and tighten thetwo sections together by hand.SPD7775.Turn the assembly several times to seat the bearings.SPD234A6.Measure the turning torque at the end of the J34309-2 gaugeanvil using Tool.Tool number: ST3127S000 (J25765-A)Turning torque specification:1.0 - 1.3 Nm(10 - 13 kg-cm, 8.7 - 11.3 in-lb)SPD208A7.PlacetheJ34309-14pinionheight adapter ontothegaugeplate and tighten it by hand.CAUTION:Make sure all machined surfaces are clean.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXADJUSTMENTH190APinion Gear Height (Contd)PD-43SPD218APINION HEIGHT ADJUSTING WASHER SELECTION8. Now, positionthesidebearingdiscs, J25269-18, andarborfirmly into the side bearing bores.SPD219A9. Install the side bearing caps and torque the cap bolts.Specification:49 - 59 Nm (5 - 6 kg-m, 36 - 43 ft-lb)SPD204A10. Select thecorrect standardpinionheight adjustingwasherthickness by using J34309-101 feeler gauge. Measure the gapbetween the J34309-14 pinion height adapter and the arbor.SPD77811. Write down your exact total measurement.SPD54212. Correct the pinion height washer size by referring to the pinionhead number.Therearetwonumberspaintedonthepiniongear.Thefirstone refers to the pinion and ring gear as a matched set andshould be the same as the number on the ring gear. The sec-ond number is the pinion head height number, and it refersto the ideal pinion height from standard for quietest operation.ADJUSTMENTH190APinion Gear Height (Contd)PD-44Use the following chart to determine the correct pinion heightwasher.Pinion Head Height NumberAdd or Remove from the StandardPinion Height Washer ThicknessMeasurement6 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)+5 Subtract 0.05 mm (0.0020 in)+6 Subtract 0.06 mm (0.0024 in)13. Select the correct pinion height washer.Drive pinion height adjusting washer:Refer to SDS, PD-73.SPD220A14. Remove the J34309 pinion preload shim selector Tool from thefinal drivehousinganddisassembletoretrievethepinionbearings.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXADJUSTMENTH190APinion Gear Height (Contd)PD-45Tooth ContactCheckingof gear toothcontact patternis necessary toverifycorrect relationship between ring gear and drive pinion.Hypoid gear sets which are not positioned properly may be noisy,or have short life, or both. With a pattern check, the most desirablecontact for low noise level and long life can be assured.SPD0051. Thoroughly clean ring gear and drive pinion teeth.2. Sparingly apply a mixture of powdered ferric oxide and oil orequivalent to 3 or 4 teeth of ring gear drive side.SPD0063. Hold companion flange steady and rotate the ring gear in bothdirections.APD018ADJUSTMENTH190APD-46SPD552Differential Case1. Install side gears, pinion mate gears and thrust washers intodifferential case.SPD8282. Fit pinion mate shaft to differential case so that it meets lockpin holes.3. Adjust backlash between side gear and pinion mate gear byselecting side gear thrust washer. Refer to SDS, PD-73.Backlash between side gear and pinion mate gear(Clearance between side gear thrust washer and dif-ferential case):Less than 0.15 mm (0.0059 in)SPD0304. Install pinion mate shaft lock pin with a punch.Make sure lock pin is flush with case.SPD3225. Apply gear oil to gear tooth surfaces and thrust surfaces andcheck to see they turn properly.SPD6006. Apply locking agent [Locktite (stud lock) or equivalent] to con-tacting surfaces of ring gear and differential case, then placedifferential case on ring gear.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXASSEMBLYH190APD-47SPD0327. Apply a small amount of locking agent (described on previouspage) to ring gear bolts.8. Install new lock straps and ring gear bolts.G Tighten bolts in a criss-cross fashion, lightly tapping bolthead with a hammer.G Then bend up lock straps to lock the bolts in place.PD3539. Select side bearing adjusting shims.Refer to ADJUSTMENT, PD-41.10. Install theshims behindeachbearingandpress onsidebearing inner cones with Tools.Tool numbers:A ST33230000 (J25805-01)B ST33061000 (J8107-2)SPD580Differential Carrier1. Press-fit front and rear bearing outer races with Tools.Tool numbers:A ST30611000 (J25742-1)B ST30621000 (J25742-5)C ST30613000 (J25742-3)SPD3772. Select pinion height adjusting washer. Refer toADJUSTMENT, PD-42.3. Install pinionheight adjustingwasher indrivepinion, andpress-fit rear bearing inner cone with press and Tool.Tool number: ST30901000 (J26010-01)ASSEMBLYH190ADifferential Case (Contd)PD-48SPD5814. Place pinion front bearing inner cone in gear carrier.SPD291A5. Apply multi-purpose grease to cavity at sealing lips of oil seal.Install front oil seal.Tool numbers:A ST30720000 (J25405)B KV38102510 ( )SPD5826. Install drive pinion washer, collapsible spacer and drive pinionin gear carrier.SPD0397. Install companion flange and hold it firmly.Insert pinion into companion flange by tapping its head with asoft hammer.SPD0408. Temporarily tighten pinion nut until there is no axial play.The threaded portion of drive pinion and pinion nut should befree from oil or grease.Tool number: ST38060002 (J34311)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXASSEMBLYH190ADifferential Carrier (Contd)PD-49SPD149SPD0119.Tighten pinion nut by degrees to the specified preload whilechecking the preload with Tools.Whencheckingpreload, turndrivepinioninbothdirectionsseveral times to seat bearing rollers correctly.Pinion bearing preload:1.1 - 1.6 Nm (11 - 16 kg-cm, 9.5 - 13.9 in-lb)Tool number: ST3127S000 (J25765-A)CAUTION:The preload is achieved by the permanent setting of the col-lapsible spacer. So, if an overpreload results from turning ofthe pinion nut excessively, the spacer should be replaced bynew one.10. Install differential case assembly with side bearing outer racesinto gear carrier.SPD04311. Align mark on bearing cap with that on gear carrier and installbearing cap on gear carrier.SPD14012. Measure ring gear-to-drive pinion backlash with a dial indica-tor.Ring gear-to-drive pinion backlash:0.13 - 0.18 mm (0.0051 - 0.0071 in)GIf backlash is too small, decrease thickness of left shim andincrease thickness of right shim by the same amount.GIf backlash is too great, reverse the above procedure.Never change the total amount of shims as it will change thebearing preload.SPD14913. Check total preload with Tool.Whencheckingpreload, turndrivepinioninbothdirectionsseveral times to set bearing rollers.Tool number: ST3127S000 (J25765-A)Total preload:1.2 - 2.2 Nm (12 - 22 kg-cm, 10 - 19 in-lb)ASSEMBLYH190ADifferential Carrier (Contd)PD-50SPD031GIf preload is too great, remove the same amount of shims fromeach side.G If preload is too small, add the same amount of shims to eachside.Never add or remove a different number of shims for each sideas it will change ring gear-to-drive pinion backlash.14. Recheck ring gear-to-drive pinion backlash because anincrease or decrease in thickness of shims will cause changeof ring gear-to-pinion backlash.SPD14115. Check runout of ring gear with a dial indicator.Runout limit: 0.08 mm (0.0031 in)G If backlash varies excessively in different places, the variancemay have resulted from foreign matter caught between the ringgear and the differential case.G If the backlash varies greatly when the runout of the ring gearis within a specified range, the hypoid gear set or differentialcase should be replaced.16. Check tooth contact.Refer to ADJUSTMENT, PD-46.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXASSEMBLYH190ADifferential Carrier (Contd)PD-512WD modelsSPD425AREAR FINAL DRIVEC200PD-524WD modelsAPD010GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXREAR FINAL DRIVEC200PD-53PD245Pre-inspectionBefore disassembling final drive, perform the following inspection.G Total preloada. Turn drive pinion in both directions several times to set bearingrollers.b. Check total preload with Tool.Tool number: ST3127S000 (J25765-A)Total preload:1.2 - 2.3 Nm(12 - 23 kg-cm, 10 - 20 in-lb)SPD196GRing gear-to-drive pinion backlash.Checkbacklashof ringgearwithadial indicatorat severalpoints.Ring gear-to-drive pinion backlash:0.13 - 0.18 mm (0.0051 - 0.0071 in)SPD702GRing gear runoutCheck runout of ring gear with a dial indicator.Runout limit: 0.05 mm (0.0020 in)SPD198GTooth contactCheck tooth contact. Refer to ADJUSTMENT, PD-64.G Side gear-to-pinion mate gear backlashMeasure clearance between side gear thrust washer anddifferential case with a feeler gauge.Clearance between side gear thrust washer and differ-ential case:Less than 0.15 mm (0.0059 in)SPD714Differential Carrier1. Remove rear cover and rear cover gasket.2. Put match marks on one side of side bearing cap with paint orpunch to ensure that it is replaced in proper position duringreassembly.Bearingcapsareline-boredduringmanufactureandshouldbe put back in their original places.DISASSEMBLYC200PD-54SPD2023. Remove side bearing caps.SPD1934. Remove differential case assembly with pry bar.SPD745Keep the side bearing outer races together with their respectiveinner cones do not mix them up.SPD2045. Remove pinion nut with Tool.Tool number: ST38060002 (J34311)SPD0146. Remove companion flange with puller.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDISASSEMBLYC200Differential Carrier (Contd)PD-55SPD2067. Remove drive pinion with soft hammer.8. Remove front oil seal and pinion front bearing inner cone.PD3499. Remove pinion bearing outer races with a brass drift.PD17910. Removepinionrear bearinginner coneandpinionheightadjusting washer.Tool number: ST30031000 (J22912-01)SPD529Differential Case1. Remove side bearing inner cones.To prevent damage to bearing, engage puller jaws in grooves.Tool numbers:A ST33051001 (J22888-20)B ST33061000 (J8107-2)DISASSEMBLYC200Differential Carrier (Contd)PD-56SPD022Be careful not to confuse the right and left hand parts.SPD0242. Loosen ring gear bolts in a criss-cross fashion.3. Tap ring gear off the differential case with a soft hammer.Tap evenly all around to keep ring gear from binding.SPD0254. Punch off pinion mate shaft lock pin from ring gear side.Lock pin is calked at pin hole mouth on differential case.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDISASSEMBLYC200Differential Case (Contd)PD-57Ring Gear and Drive PinionCheck gear teeth for scoring, cracking or chipping. If any damagedpart is evident, replace ring gear and drive pinion as a set (hypoidgear set).SPD584Differential Case AssemblyCheck mating surfaces of differential case, side gears, pinion mategears, pinion mate shaft, thrust block and thrust washers.SPD715Bearing1. 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.INSPECTIONC200PD-58For quiet and reliable final drive operation, the following fiveadjustments must be made correctly.1.Side bearing preload2.Pinion gear height3.Pinion bearing preload. Refer to ASSEMBLY, PD-67.4.Ring gear-to-pinion backlash. Refer to ASSEMBLY, PD-68.5.Ring and pinion gear tooth contact patternSide Bearing PreloadA selection of carrier side bearing preload shims is requiredfor successful completion of this procedure.SPD9191.Make sure all parts are clean. Make sure, also, the bearingsare well lubricated with light oil or type DEXRONTM automatictransmission fluid.2.Place the differentialcarrier, with side bearings and bearingraces installed, into the final drive housing.SPD8943.Put the side bearing spacer in place.CAUTION:Side bearing spacer is placed on either the right or leftdepending upon final drive gear ratio. Be sure to replace it onthe correct side.SPD9864.Use Tool to place original carrier side bearing preload shims onthe carrier end, opposite the ring gear.Tool number: KV38100600 (J25267)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXADJUSTMENTC200PD-59SPD5265. Install thesidebearingcapsintheir correct locationsandtorque the bearing cap retaining bolts.Specification:88 - 98 Nm(9.0 - 10.0 kg-m, 65 - 72 ft-lb)6. Turn the carrier several times to seat the bearings.SPD194A7. Measuretheturningtorqueof thecarrier at theringgearretaining 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 boltSPD7728. If the turning torque is not within the specifications, correct thetorque as follows:G If theturningtorqueislessthanthespecifiedrange, installwashers of greater thickness.G If theturningtorqueisgreaterthanthespecification, installthinner washers.G See the SDS section for washer dimensions and part numbers.9. Record the total amount of washer thickness required for thecorrect carrier side bearing preload.PD34410. Removethecarrier fromthefinal drivehousing. Savetheselected preload washers for later use during the assembly ofthe final drive unit.SPD769Pinion Gear Height1. Make sure all parts are clean and that the bearings are welllubricated.2. Assemble the pinion gear bearings into the pinion preload shimselector Tool, J34309.ADJUSTMENTC200Side Bearing Preload (Contd)PD-60SPD197AGFront pinion bearing make sure the J34309-3 front pinionbearingseat issecuredtightlyagainst theJ34309-2gaugeanvil. Thenturnthefront pinionbearingpilot, J34309-5, tosecure the bearing in its proper position.G Rear pinion bearing the rear pinion bearing pilot,J34309-8, is used to center the rear pinion bearing only. Therear pinion bearing locking seat, J34309-4, is used to lock thebearing to the assembly.SPD8933. Installthe pinion rear bearing inner cone into the finaldrivehousing. Thenplacethepinionpreloadshimselector Tool,J34309-1, gauge screw assembly.SPD199A4. Assemble the front pinion bearing inner cone and the J34309-2gauge anvil. Assemble them together with the J34309-1 gaugescrewinthefinal drivehousing. Makesurethat thepinionheight gaugeplate, J34309-16, will turnafull 360degrees.Tighten the two sections together by hand.SPD7705. Turn the assembly several times to seat the bearings.SPD234A6. Measure the turning torque at the end of the J34309-2 gaugeanvil using Tool.Tool number: ST3127S000 (J25765-A)Turning torque specification:1.0 - 1.3 Nm(10 - 13 kg-cm, 8.7 - 11.3 in-lb)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXADJUSTMENTC200Pinion Gear Height (Contd)PD-61SPD208A7.PlacetheJ34309-11pinionheight adapter ontothegaugeplate and tighten it by hand.CAUTION:Make sure all machined surfaces are clean.SPD211APINION HEIGHT ADJUSTING WASHERSELECTION8.Now, positionthesidebearingdiscs, J25269-4, andarborfirmly into the side bearing bores.Install the side bearing caps and tighten the cap bolts to propertorque.SPD204A9.Select thecorrect standardpinionheight adjustingwasherthickness. Select by using a standard gauge of 3 mm (0.12 in)and J34309-101 feeler gauge. Measure the distance betweentheJ34309-11pinionheight adapter includingthestandardgauge and the arbor.SPD77510. Write down your exact measurement (the value of feelergauge).ADJUSTMENTC200Pinion Gear Height (Contd)PD-62SPD54211. Correct the pinion height washer size by referring to the pinionhead number.Therearetwonumberspaintedonthepiniongear.Thefirstone refers to the pinion and ring gear as a matched set. Thisnumber should be the same as the number on the ring gear.Thesecondnumberisthepinionheadheight number. Itreferstotheideal pinionheight fromstandardfor quietestoperation. Usethefollowingchart todeterminethecorrectpinion height washer.Use the following chart to determine the correct pinion heightwasher:Pinion head heightnumberAdd or remove from the standard pinion heightwasher thickness measurement6 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)+5 Subtract 0.05 mm (0.0020 in)+6 Subtract 0.06 mm (0.0024 in)12. Select the correct pinion height washer.Drive pinion height adjusting washer:Refer to SDS, PD-74.SPD205A13. Remove the J34309 pinion preload shim selector Tool from thefinal drivehousing. Thendisassembletoretrievethepinionbearings.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXADJUSTMENTC200Pinion Gear Height (Contd)PD-63Tooth ContactChecking gear tooth contact pattern is necessary to verify correctrelationship between ring gear and drive pinion.Hypoid gear set which is not positioned properly may be noisy, orhaveshort lifeorboth. Withthecheckingorgeartoothcontactpattern, the most desirable contact for low noise level and long lifecan be assured.SPD1991. Thoroughly clean ring gear and drive pinion teeth.2. Sparingly apply a mixture of powdered ferric oxide and oil orequivalent to 3 or 4 teeth of ring gear drive side.SPD2003. Hold companion flange steady and rotate the ring gear in bothdirections.APD018ADJUSTMENTC200PD-64SPD656Differential Case1. Measure clearance between side gear thrust washer anddifferential case.Clearance between side gear thrust washerand differential case (A B):Less than 0.15 mm (0.0059 in)The clearance can be adjusted with side gear thrust washer.Refer to SDS, PD-74.2. Apply gear oil to gear tooth surfaces and thrust surfaces andcheck to see they turn properly.SPD6433. Install differential case LH and RH.SPD7464. Place differential case on ring gear.5. Apply locking agent [Locktite (stud lock) or equivalent] to ringgear bolts, and install them.Tighten bolts in a criss-cross fashion, lightly tapping bolt headwith a hammer.PD3536. Press-fit side bearing inner cones on differential case with Tool.Tool numbers:A ST33230000 (J25805-01)B ST33061000 (J8107-2)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXASSEMBLYC200PD-65SPD679Differential Carrier1. Press-fit front and rear bearing outer races with Tools.Tool numbers:A ST30611000 (J25742-1)B ST30621000 (J25742-5)C ST30613000 (J25742-3)SPD3772. Select pinion height adjusting washer. Refer toADJUSTMENT, PD-60.3. Install pinionheight adjustingwasher indrivepinion, andpress-fit rear bearing inner cone in it, with press and Tool.Tool number: ST30901000 (J26010-01)SPD5814. Place pinion front bearing inner cone in gear carrier.SPD5575. Apply multi-purpose grease to cavity at sealing lips of oil seal.Install front oil seal.Tool number: KV38100500 (J25273)ASSEMBLYC200PD-66SPD2226. Place drive pinion bearing spacer, drive pinion bearingadjusting washer and drive pinion in gear carrier.SPD7087. Insert companion flange into drive pinion by tapping thecompanion flange with a soft hammer.SPD2048. Tighten pinion nut to 127 Nm (13 kg-m, 94 ft-lb).The threaded portion of drive pinion and pinion nut should befree from oil or grease.Tool number: ST38060002 (J34311)SPD241SPD2039. Tighten the pinion nut by very small degrees until the specifiedpreload is achieved. When checking the preload, turn the drivepinion in both directions several times to set the bearing rollers.Tool number: ST3127S000 (J25765-A)Pinion bearing preload:1.1 - 1.7 Nm(11 - 17 kg-cm, 9.5 - 14.8 in-lb)This procedure will have to be repeated if:G Maximum preload is achieved before the minimum pinionnut torque is reached.G Minimum preload is not achieved before maximum pinionnut torque is reached.10. Select side bearing adjusting washer.Refer to Adjustment PD-59.11. Install differential case assembly with side bearing outer racesinto gear carrier.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXASSEMBLYC200Differential Carrier (Contd)PD-67SPD55812. Insert left andright sidebearingadjustingwashersinplacebetween side bearing and carrier.SPD70913. Drive in side bearing spacer with Tool.Tool number: KV38100600 (J25267)SPD22614. Align mark on bearing cap with that on gear carrier and installbearing cap on gear carrier.SPD19615. Measure ring gear-to-drive pinion backlash with a dial indicator.Ring gear-to-drive pinion backlash:0.13 - 0.18 mm(0.0051 - 0.0071 in)G If backlash is too small, decrease thickness of right shim andincrease 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 thebearing preload.SPD24116. Check total preload with Tool.Whencheckingpreload, turndrivepinioninbothdirectionsseveral times to seat bearing rollers correctly.Total preload:1.2 - 2.3 Nm(12 - 23 kg-cm, 10 - 20 in-lb)Tool number: ST3127S000 (J25765-A)ASSEMBLYC200Differential Carrier (Contd)PD-68SPD561GIf preload is too great, remove the same amount of shim fromeach side.G If preload is too small, add the same amount of shim to eachside.Never add or remove a different number of shims for each sideas it will change ring gear-to-drive pinion backlash.17. Recheck ring gear-to-drive pinion backlash because increaseor decrease in thickness of shims willcause change of ringgear-to-pinion backlash.SPD70218. Check runout of ring gear with a dial indicator.Runout limit:0.05 mm (0.0020 in)G If backlash varies excessively in different places, the variancemay have resulted from foreign matter caught between the ringgear and the differential case.G If the backlash varies greatly when the runout of the ring gearis within a specified range, the hypoid gear set or differentialcase should be replaced.19. Check tooth contact.Refer to ADJUSTMENT, PD-64.20. Install rear cover and gasket.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXASSEMBLYC200Differential Carrier (Contd)PD-69Propeller ShaftGENERAL SPECIFICATIONS2WD modelsApplied modelStandard wheelbase Long wheelbaseM/T A/T M/T A/TPropeller shaft model 2S1310 3S1310Number of joints 2 3Coupling method withtransmissionSleeve typeType of journal bearings Solid type (disassembly type)Shaft length(Spider to spider)1st 1323.3 549.6 644.7 549.6mm (in) 2nd 675.5 975.5 970.3Shaft diameter 1st 88.9 63.5mm (in) 2nd 63.54WD modelsLocation Front RearApplied modelStandardwheelbaseLongwheelbaseStandardwheelbaseLongwheelbasePropeller shaft model 2F1310 2S1310 3S1310Number of joints 2 3Coupling method with transmission Flange type Sleeve typeType of journal bearings Solid type (disassembly type)Shaft length(Spider to spider)1st 542 968 392.1mm (in) 2nd 873.9Shaft diameter 1st 63.5mm (in) 2nd 63.5SERVICE DATA Unit: mm (in)Propeller shaft runout limit 0.6 (0.024)Journal axial play 0.02 (0.0008) or lessSnap ring Unit: mm (in)Thickness Color Part number1.99 (0.0783) White 37146-C94002.02 (0.0795) Yellow 37147-C94002.05 (0.0807) Red 37148-C94002.08 (0.0819) Green 37149-C94002.11 (0.0831) Blue 37150-C94002.14 (0.0843) Light brown 37151-C94002.17 (0.0854) Black 37152-C94002.20 (0.0866) No paint 37153-C9400SERVICE DATA AND SPECIFICATIONS (SDS)PD-70Final DriveGENERAL SPECIFICATIONS2WD modelsTransmission M/T A/TBody type Regular cab King cab Regular cab King cabFinal drive modelH190A H190A H190A C2002-pinion 2-pinion 2-pinion 2-pinionGear ratio 3.545 3.700 3.889 4.375Number of teeth(Ring gear/drive pinion)39/11 37/10 35/9 35/8Oil capacity (Approx.)l (US pt, Imp pt)1.5(3-1/8, 2-5/8)1.3(2-3/4, 2-1/4)1.5(3-1/8, 2-5/8)1.3(2-3/4, 2-1/4)4WD modelsFront final driveR180A4-pinionGear ratio 4.625Oil capacity (Approx.)l (US pt, Imp pt)1.3 (2-3/4, 2-1/4)Rear final drive C2004-pinionGear ratio 4.625Number of teeth(Ring gear/drive pinion)37/8Oil capacity (Approx.)l (US pt, Imp pt)1.3 (2-3/4, 2-1/4)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXSERVICE DATA AND SPECIFICATIONS (SDS)PD-71INSPECTION AND ADJUSTMENT (R180A)Ring gear runoutRing gear runout limit mm (in) 0.05 (0.0020)Axle bearing adjustmentAxle bearing end play mm (in) 0 - 0.1 (0 - .0039 or less)Available axle bearing adjusting shimsThickness mm (in) Part number0.10 (0.0039)0.20 (0.0079)0.30 (0.0118)0.40 (0.0157)38233-01G1138233-01G1238233-01G1338233-01G14Side gear adjustmentSide gear backlash(Clearance between side gear anddifferential case) mm (in)Less than 0.15 (0.0059)Available side gear thrust washersThickness mm (in) Part number0.75 (0.0295)0.78 (0.0307)0.81 (0.0319)0.84 (0.0331)0.87 (0.0343)0.90 (0.0354)0.93 (0.0366)0.96 (0.0378)38424-W201038424-W201138424-W201238424-W201338424-W201438424-W201538424-W201638424-W2017Side bearing adjustmentDifferential carrier assembly turningresistanceN (kg, lb)34.3 - 39.2(3.5 - 4.0, 7.7 - 8.8)Side bearing adjusting method Adjusting shimAvailable side retainer shimsThickness mm (in) Part number0.20 (0.0079)0.25 (0.0098)0.30 (0.0118)0.40 (0.0157)0.50 (0.0197)38453-01G0038453-01G0138453-01G0238453-01G0338453-01G04Total preload adjustmentTotal preloadNm (kg-cm, in-lb)1.2 - 2.3(12 - 23, 10 - 20)Ring gear backlash mm (in)0.13 - 0.18(0.0051 - 0.0071)Drive pinion height adjustmentAvailable pinion height adjusting washersThickness mm (in) Part number3.09 (0.1217)3.12 (0.1228)3.15 (0.1240)3.18 (0.1252)3.21 (0.1264)3.24 (0.1276)3.27 (0.1287)3.30 (0.1299)3.33 (0.1311)3.36 (0.1323)3.39 (0.1335)3.42 (0.1346)3.45 (0.1358)3.48 (0.1370)3.51 (0.1382)3.54 (0.1394)3.57 (0.1406)3.60 (0.1417)3.63 (0.1429)3.66 (0.1441)38154-P601738154-P601838154-P601938154-P602038154-P602138154-P602238154-P602338154-P602438154-P602538154-P602638154-P602738154-P602838154-P602938154-P603038154-P603138154-P603238154-P603338154-P603438154-P603538154-P6036Drive pinion preload adjustmentDrive pinion bearing preloadadjusting methodAdjusting washerand spacerDrive pinion preloadNm (kg-cm, in-lb)Without front oil seal1.0 - 1.6(10 - 16, 8.7 - 14)With front oil seal1.1 - 1.7(11 - 17, 9.5 - 14.8)Available drive pinion bearing preload adjusting washersThickness mm (in) Part number6.58 - 6.60 (0.2591 - 0.2598)6.56 - 6.58 (0.2583 - 0.2591)6.54 - 6.56 (0.2575 - 0.2583)6.52 - 6.54 (0.2567 - 0.2575)6.50 - 6.52 (0.2559 - 0.2567)6.48 - 6.50 (0.2551 - 0.2559)6.46 - 6.48 (0.2543 - 0.2551)6.44 - 6.46 (0.2535 - 0.2543)6.42 - 6.44 (0.2528 - 0.2535)6.40 - 6.42 (0.2520 - 0.2528)6.38 - 6.40 (0.2512 - 0.2520)6.36 - 6.38 (0.2504 - 0.2512)6.34 - 6.36 (0.2496 - 0.2504)6.32 - 6.34 (0.2488 - 0.2496)6.30 - 6.32 (0.2480 - 0.2488)38127-01G0038127-01G0138127-01G0238127-01G0338127-01G0438127-01G0538127-01G0638127-01G0738127-01G0838127-01G0938127-01G1038127-01G1138127-01G1238127-01G1338127-01G14Available drive pinion bearing preload adjusting spacersLength mm (in) Part number52.20 (2.0551)52.40 (2.0630)52.60 (2.0709)52.80 (2.0787)53.00 (2.0866)53.20 (2.0945)38130-7850038131-7850038132-7850038133-7850038134-7850038135-78500SERVICE DATA AND SPECIFICATIONS (SDS)Final Drive (Contd)PD-72INSPECTION AND ADJUSTMENT (H190A)Ring gear runoutRing gear runout limit mm (in) 0.08 (0.0031)Side gear adjustmentSide gear backlash(Clearance between side gear todifferential case) mm (in)Less than 0.15 (0.0059)Available side gear thrust washersThickness mm (in) Part number0.75 (0.0295)0.80 (0.0315)0.85 (0.0335)0.90 (0.0354)38424-E300038424-E300138424-E300238424-E3003Drive pinion height adjustmentAvailable drive pinion height adjusting washersThickness mm (in) Part number2.58 (0.1016)2.61 (0.1028)2.64 (0.1039)2.67 (0.1051)2.70 (0.1063)2.73 (0.1075)2.76 (0.1087)2.79 (0.1098)2.82 (0.1110)2.85 (0.1122)2.88 (0.1134)2.91 (0.1146)2.94 (0.1157)2.97 (0.1169)3.00 (0.1181)3.03 (0.1193)3.06 (0.1205)3.09 (0.1217)3.12 (0.1228)3.15 (0.1240)3.18 (0.1252)38154-P600038154-P600138154-P600238154-P600338154-P600438154-P600538154-P600638154-P600738154-P600838154-P600938154-P601038154-P601138154-P601238154-P601338154-P601438154-P601538154-P601638154-P601738154-P601838154-P601938154-P6020Drive pinion preload adjustmentDrive pinion bearing preload adjust-ing methodCollapsible spacerDrive pinion preloadNm (kg-cm, in-lb)With front oil seal1.1 - 1.6(11 - 16, 9.5 - 13.9)Side bearing adjustmentDifferential carrier assembly turningresistance N (kg, lb)34.3 - 39.2(3.5 - 4.0, 7.7 - 8.8)Side bearing adjusting method Adjusting shimAvailable side bearing adjusting shimsThickness mm (in) Part number0.10 (0.0039)0.12 (0.0047)0.15 (0.0059)0.17 (0.0067)0.20 (0.0079)0.25 (0.0098)0.30 (0.0118)0.40 (0.0157)0.50 (0.0197)38455-6120038453-6120138453-6120238453-6120338456-6120038453-6120438453-6120538453-6120638457-61200Total preload adjustmentTotal preloadNm (kg-cm, in-lb)1.2 - 2.2(12 - 22, 10 - 19)Ring gear backlash mm (in)0.13 - 0.18(0.0051 - 0.0071)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXSERVICE DATA AND SPECIFICATIONS (SDS)Final Drive (Contd)PD-73INSPECTION AND ADJUSTMENT (C200)Ring gear runoutRing gear runout limit mm (in) 0.05 (0.0020)Side gear adjustmentSide gear backlash(Clearance between side gear anddifferential case) mm (in)Less than 0.15 (0.0059)Available side gear thrust washers (2WD)Thickness mm (in) Part number0.75 (0.0295)0.78 (0.0307)0.81 (0.0319)0.84 (0.0331)0.87 (0.0343)0.90 (0.0354)0.93 (0.0366)38424-N311038424-N311138424-N311238424-N311338424-N311438424-N311538424-N3116Available side gear thrust washers (4WD)Thickness mm (in) Part number0.75 (0.0295)0.80 (0.0315)0.85 (0.0335)0.90 (0.0354)38424-E300038424-E300138424-E300238424-E3003Side bearing adjustmentDifferential carrier assembly turningresistance N (kg, lb)34.3 - 39.2(3.5 - 4.0, 7.7 - 8.8)Available side bearing adjusting washersThickness mm (in) Part number2.00 (0.0787)2.05 (0.0807)2.10 (0.0827)2.15 (0.0846)2.20 (0.0866)2.25 (0.0886)2.30 (0.0906)2.35 (0.0925)2.40 (0.0945)2.45 (0.0965)2.50 (0.0984)2.55 (0.1004)2.60 (0.1024)38453-N310038453-N310138453-N310238453-N310338453-N310438453-N310538453-N310638453-N310738453-N310838453-N310938453-N311038453-N311138453-N3112Drive pinion height adjustmentAvailable pinion height adjusting washersThickness mm (in) Part number3.09 (0.1217)3.12 (0.1228)3.15 (0.1240)3.18 (0.1252)3.21 (0.1264)3.24 (0.1276)3.27 (0.1287)3.30 (0.1299)3.33 (0.1311)3.36 (0.1323)3.39 (0.1335)3.42 (0.1346)3.45 (0.1358)3.48 (0.1370)3.51 (0.1382)3.54 (0.1394)3.57 (0.1406)3.60 (0.1417)3.63 (0.1429)3.66 (0.1441)38154-P601738154-P601838154-P601938154-P602038154-P602138154-P602238154-P602338154-P602438154-P602538154-P602638154-P602738154-P602838154-P602938154-P603038154-P603138154-P603238154-P603338154-P603438154-P603538154-P6036Drive pinion preload adjustmentDrive pinion bearing preloadadjusting methodCollapsible spacerDrive pinion preloadNm (kg-cm, in-lb)Without front oil seal1.0 - 1.6(10 - 16, 8.7 - 14)With front oil seal1.1 - 1.7(11 - 17, 9.5 - 15)Total preload adjustmentTotal preloadNm (kg-cm, in-lb)1.2 - 2.3(12 - 23, 10 - 20)Ring gear backlash mm (in)0.13 - 0.18(0.0051 - 0.0071)SERVICE DATA AND SPECIFICATIONS (SDS)Final Drive (Contd)PD-74