Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 1998-2002 Approved Nissan Frontier 2000 VG33E PD

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                                                                                           PROPELLER SHAFT &                                                                  GI
                                                                                         DIFFERENTIAL CARRIER
                                                                                                                                                                              MA


                                                                                                     SECTION                                  PD                              EM

                                                                                                                                                                              LC

                                                                                                                                                                              EC

                                                                  CONTENTS                                                                                                    FE

PREPARATION................................................................3             INSPECTION..................................................................23
                                                                                                                                                                              CL
  Special Service Tools ..................................................3                Ring Gear and Drive Pinion ......................................23
NOISE, VIBRATION AND HARSHNESS (NVH)                                                       Differential Case Assembly........................................23
TROUBLESHOOTING .....................................................7                     Bearing.......................................................................23   MT
  NVH Troubleshooting Chart.........................................7                    ADJUSTMENT ...............................................................24
                                                                                           Side Bearing Preload.................................................24
                          PROPELLER SHAFT                                                  Pinion Gear Height and Pinion Bearing Preload.......25                             AT
                                                                                              Pinion Bearing Preload Washer Selection............27
PROPELLER SHAFT ......................................................8                       Pinion Height Adjusting Washer Selection............28
  On-vehicle Service.......................................................9               Tooth Contact.............................................................30       TF
  Removal and Installation .............................................9                ASSEMBLY....................................................................31
  Inspection.....................................................................9         Differential Side Shaft................................................31
                                                                                           Differential Case ........................................................31       PD
  Disassembly...............................................................10
  Assembly ...................................................................11           Final Drive Housing ...................................................33
                                                                                                                                                                              FA
                                FINAL DRIVE                                                                                 H233B


ON-VEHICLE SERVICE ................................................13                    REAR FINAL DRIVE .....................................................37             RA
   Front Oil Seal Replacement ......................................13                   DISASSEMBLY..............................................................38
          (Front final drive: Model R200A) ......................13                        Pre-inspection ............................................................38
                                                                                           Differential Carrier......................................................38       BR
          (Rear final drive: Model H233B).......................13
REMOVAL AND INSTALLATION (Front final                                                      Differential Case ........................................................40
drive)..............................................................................15   INSPECTION..................................................................42
                                                                                           Ring Gear and Drive Pinion ......................................42
                                                                                                                                                                              ST
   Removal.....................................................................15
   Installation..................................................................15        Differential Case Assembly........................................42
REMOVAL AND INSTALLATION (Rear final drive) ....16                                         Bearing.......................................................................42   RS
   Removal.....................................................................16        LIMITED SLIP DIFFERENTIAL.....................................43
   Installation..................................................................16        Preparation for Disassembly .....................................43
                                                                                              Checking Differential Torque .................................43                BT
                                                                                           Disassembly...............................................................43
                                     R200A
                                                                                           Inspection...................................................................44
                                                                                              Contact Surfaces...................................................44           HA
FRONT FINAL DRIVE ...................................................17                       Disc And Plate.......................................................44
DISASSEMBLY..............................................................18                Adjustment .................................................................45
  Pre-inspection ............................................................18               Friction Disc And Friction Plate End Play.............45                        EL
  Final Drive Housing ...................................................18                Assembly ...................................................................46
  Differential Case ........................................................21           ADJUSTMENT ...............................................................49
  Differential Side Shaft................................................21                Pinion Gear Height ....................................................49
                                                                                                                                                                              IDX
                                                   CONTENTS                            (Cont'd.)
     Pinion Height Adjusting Washer Selection............50                           General Specifications ..........................................58
  Tooth Contact.............................................................52        Inspection And Adjustment (R200A) .....................58
ASSEMBLY....................................................................53           Ring gear runout...............................................58
  Differential Case ........................................................53           Side gear adjustment .......................................58
  Differential Carrier......................................................54           Side bearing adjustment...................................58
SERVICE DATA AND SPECIFICATIONS (SDS) ..........57                                    Inspection And Adjustment (H233B) .....................59
  Propeller Shaft ...........................................................57          Ring gear runout...............................................59
     General Specifications ..........................................57                 -- Additional service for LSD model --
     Inspection And Adjustment....................................57                     Differential torque adjustment...........................59
        Service data......................................................57             Drive pinion height adjustment.........................60
        Snap ring ..........................................................57           Drive pinion preload adjustment.......................60
  Final Drive..................................................................58        Total preload adjustment ..................................60




                                                                               PD-2
                                                      PREPARATION

                                                     Special Service Tools                                                          GI
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number                                                                                                      Unit application   MA
(Kent-Moore No.)            Description
Tool name                                                                                                        R200A    H233B

ST3127S000                                                             Measuring pinion bearing preload and                         EM
(See J25765-A)                                                         total preload
Preload gauge
 1 GG91030000                                                                                                                       LC
    (J25765)
    Torque wrench
 2 HT62940000
                                                                                                                  X          X      EC
    (   --   )
    Socket adapter
 3 HT62900000                                                                                                                       FE
    (   --   )
    Socket adapter          NT124
                                                                                                                                    CL
KV38100800                                                             Mounting final drive
(J34310, J25604-01)                                                    (To use, make a new hole.)
Differential attachment
                                                                                                                  X          --     MT

                            NT119                                      a: 152 mm (5.98 in)
                                                                                                                                    AT
ST06340000                                                             Mounting final drive
(J24310, J34310)
Differential attachment
                                                                                                                  --         X      TF

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


                            NT141
                                                                                                                                    RA
ST38060002                                                             Removing and installing propeller shaft
(J34311)                                                               lock nut, and drive pinion lock nut                          BR
Drive pinion flange                                                                                               X          --
wrench

                            NT113
                                                                                                                                    ST
KV38104700                                                             Removing and installing propeller shaft
(J34311)                                                               lock nut, and drive pinion lock nut                          RS
Drive pinion flange                                                                                               --         X
wrench

                            NT113                                                                                                   BT
ST3090S000                                                             Removing and installing drive pinion
(    --    )                                                           rear inner cone
                                                                                                                                    HA
Drive pinion rear inner
race puller set
  1 ST30031000
    (J22912-01)
                                                                                                                  X          X      EL
    Puller
  2 ST30901000                                                         a: 79 mm (3.11 in) dia.
    (J26010-01)                                                        b: 45 mm (1.77 in) dia.
                                                                                                                                    IDX
    Base                    NT527                                      c: 35 mm (1.38 in) dia.


                                                               PD-3
                                           PREPARATION
                                          Special Service Tools (Cont'd)
Tool number                                                                                         Unit application
(Kent-Moore No.)            Description
Tool name                                                                                           R200A    H233B

ST3306S001                                             Removing and installing differential side
Differential side bearing                              bearing inner cone
puller set
 1 ST33051001
     (J22888-20)                                                                                     X          X
     Body
 2 ST33061000
     (J8107-2)                                         a: 28.5 mm (1.122 in) dia.
     Adapter                NT072                      b: 38 mm (1.50 in) dia.
KV38100300                                             Installing side bearing inner cone
(J25523)
Differential side bearing
drift                                                                                                X          --
                                                       a: 54 mm (2.13 in) dia.
                                                       b: 46 mm (1.81 in) dia.
                            NT085                      c: 32 mm (1.26 in) dia.
ST33190000                                             Installing side bearing inner cone
(J25523)
Differential side bearing
drift                                                                                                --         X
                                                       a: 52 mm (2.05 in) dia.
                                                       b: 45.5 mm (1.791 in) dia.
                            NT085                      c: 34 mm (1.34 in) dia.
ST33081000                                             Installing side bearing inner cone
(   --    )
Side bearing puller
adapter                                                                                              --         X

                                                       a: 43 mm (1.69 in) dia.
                            NT431                      b: 33.5 mm (1.319 in) dia.
KV38100600                                             Installing side bearing spacer
(J25267)
Side bearing spacer drift
                                                                                                     X          --

                                                       a: 8 mm (0.31 in)
                            NT528                      b: R42.5 mm (1.673 in)
ST30611000                                             Installing pinion rear
(J25742-1)                                             bearing outer race
Drift                                                  (Use with ST30621000 or ST30613000)           X          X


                            NT090

ST30621000                                             Installing pinion rear bearing outer race
(J25742-5)                                             (Use with ST30611000)
Drift
                                                                                                     X          X

                                                       a: 79 mm (3.11 in) dia.
                            NT073                      b: 59 mm (2.32 in) dia.
ST30613000                                             Installing pinion front bearing outer race
(J25742-3)                                             (Use with ST30611000)
Drift
                                                                                                     X          X

                                                       a: 72 mm (2.83 in) dia.
                            NT073                      b: 48 mm (1.89 in) dia.



                                                PD-4
                                             PREPARATION
                                            Special Service Tools (Cont'd)
                                                                                                                       GI
Tool number                                                                                         Unit application
(Kent-Moore No.)              Description
Tool name                                                                                           R200A    H233B
                                                                                                                       MA
KV381025S0                                               Installing front oil seal
(    --      )
Oil seal fitting tool                                                                                                  EM
  1 ST30720000
    (J25405)                                                                                         --         X
    Drift bar                                            a: 77 mm (3.03 in) dia.                                       LC
  2 KV38102510                                           b: 55 mm (2.17 in) dia.
    (     --     )                                       c: 71 mm (2.80 in) dia.
    Drift                     NT525                      d: 65 mm (2.56 in) dia.                                       EC
KV38100500                                               Installing front oil seal
(J25273)
Gear carrier front oil seal                                                                                            FE
                                                                                                     X          --
drift
                                                         a: 85 mm (3.35 in) dia.
                              NT115                      b: 60 mm (2.36 in) dia.                                       CL
KV38100200                                               Installing side oil seal
(J26233)
Gear carrier side oil seal                                                                                             MT
                                                                                                     X          --
drift

                              NT120                                                                                    AT
(J34309)                                                 Adjusting bearing pre-load and gear
Differential shim                                        height
selector                                                                                                               TF

                                                                                                                       PD
                                                                                                     X          X


                                                                                                                       FA

                              NT134
                                                                                                                       RA
(J25269-4)                                               Selecting pinion height adjusting washer
Side bearing discs
(2 Req'd)
                                                                                                     X          --     BR

                              NT136
                                                                                                                       ST
(J25269-18)                                              Selecting pinion height adjusting washer
Side bearing discs
(2 Req'd)                                                                                            --         X      RS

                              NT135

(J8129)                                                  Measuring carrier turning torque
                                                                                                                       BT
Spring gauge

                                                                                                     X          X      HA

                              NT127
                                                                                                                       EL

                                                                                                                       IDX


                                                  PD-5
                                        PREPARATION
                                       Special Service Tools (Cont'd)
Tool number                                                                                   Unit application
(Kent-Moore No.)         Description
Tool name                                                                                     R200A    H233B

KV381052S0                                          Checking differential torque on limited
(    --   )                                         slip differential
Rear axle shaft dummy
  1 KV38105210
    (   --    )                                                                                --         X
    Torque wrench side
  2 KV38105220
    (   --    )
    Vice side            NT142




                                             PD-6
                                                                    Symptom



                            X : Applicable
                                                                                                                                                                                          Reference page




                                                                                                                           Possible cause and




                                                                        SHAFT
                                                                                                                           SUSPECTED PARTS




                                                                        PROPELLER



                                             DIFFERENTIAL
                                             Noise
                                                                                    Noise
                                                                          Shake
                                                            Vibration
                                                            X
                                                                                    X
                                                                                            Uneven rotation torque                                                                        --




                                                            X
                                                                          X
                                                                                    X
                                                                                            Center bearing improper installlation                                                    PD-8, 11




                                                            X
                                                                                    X
                                                                                            Excessive center bearing axial end play                                                       --




                                                            X
                                                                                    X
                                                                                            Center bearing mounting (insulator) cracks, damage or deterioration                           --




                                                            X
                                                                                    X
                                                                          X
                                                                                            Excessive joint angle                                                                         --




PD-7
                                                            X
                                                                                    X
                                                                                            Rotation imbalance                                                                          PD-9




                                                            X
                                                                                    X
                                                                                            Excessive runout                                                                            PD-9




                                             X
                                                                                            Rough gear tooth                                                                         PD-23, 42




                                             X
                                                                                            Improper gear contact                                                                    PD-30, 52




                                             X
                                                                                            Tooth surfaces worn                                                                      PD-23, 42




                                             X
                                                                                            Incorrect backlash                                                                       PD-35, 56




                                             X
                                                                                            Companion flange excessive runout                                                             --
                                                                                                                                                                                                                                                                                                                                        NVH Troubleshooting Chart




                                             X
                                                                                            Improper gear oil                                                       Refer to MA section




                                             X
                                                                                            PROPELLER SHAFT                                                         Refer to PROPELLER SHAFT in this chart




                                                                                    X
                                                                                            DIFFERENTIAL                                                            Refer to DIFFERENTIAL in this chart




                                             X
                                                            X
                                                                                    X
                                                                          X
                                                                                            DRIVE SHAFT                                                             NVH in FA section




                                             X
                                                            X
                                                                                    X
                                                                          X
                                                                                            AXLE AND SUSPENSION                                                     NVH in FA, RA section




                                             X
                                                            X
                                                                                    X
                                                                          X
                                                                                            TIRES                                                                   NVH in FA section
                                                                                                                                                                                                                                                                                                                                                                    NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING




                                             X
                                                                                    X
                                                                          X
                                                                                            ROAD WHEEL                                                              NVH in FA section




                                             X
                                                                                    X
                                                                          X
                                                                                            BRAKES                                                                  NVH in BR section
                                                                                                                                                                                                                          Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.




                                             X
                                                            X
                                                                                    X
                                                                          X
                                                                                            STEERING                                                                NVH in ST section
                                                                                                                                                                                                                                                                                                                                                 GI




                                                                                                                                                TF
                                                                                                                                                     AT




             EL
                                                                                                                                                                       FE




                                                                              ST
                                                                                                                 FA




                       BT
                                                                                                                                                               CL
                                                                                                                                                                                                           LC




                                             RS
                                                                                                                                                                                EC




                                                                                                      RA




                  HA
                                                                                             BR
                                                                                                                                                          MT




                                                                                                                         PD
                                                                                                                                                                                                                EM
                                                                                                                                                                                                                     MA




       IDX
                                 PROPELLER SHAFT   PROPELLER SHAFT


Front propeller shaft (Model 2F1310)




                                                              APD025


Rear propeller shaft (Model 3S1310)




                                                              WPD017


                                       PD-8
         PROPELLER SHAFT                             PROPELLER SHAFT


          On-vehicle Service                                                       GI
          PROPELLER SHAFT VIBRATION
          If vibration is present at high speed, inspect propeller shaft runout    MA
          first.
          1. Raise rear end of vehicle until wheels are clear of the ground.
          2. Measure propeller shaft runout at several points along propel-        EM
                 ler shaft by rotating final drive companion flange using hands.
          3. If runout exceeds specifications, disconnect propeller shaft at
                 final drive companion flange. Rotate companion flange 180         LC
SPD728
                 degrees, then reconnect propeller shaft.
                     Runout limit: 0.6 mm (0.024 in)
          4. Check runout again. If runout still exceeds the limit, replace        EC
                 propeller shaft assembly.
          5. Perform road test.
                                                                                   FE
          APPEARANCE CHECKING
          q    Inspect propeller shaft tube surface for dents or cracks and
               replace as necessary.                                        CL
          q    Check center bearing for noise or damage and replace as
               necessary.
                                                                                   MT
SPD102


          Removal and Installation                                                 AT
          1.   Place matching marks on flanges, then separate propeller
               shaft from final drive.                                  TF

                                                                                   PD

                                                                                   FA
SPD103

          2.   Remove propeller shaft.                                      RA
          q    Insert plug into rear oil seal after removing rear propeller
               shaft.
                                                                                   BR

                                                                                   ST

                                                                                   RS
SPD359
                                                                                   BT
          Inspection
          q    Inspect propeller shaft runout. If runout exceeds the limit,
               replace propeller shaft assembly.                            HA
                  Runout limit: 0.6 mm (0.024 in)

                                                                                   EL

                                                                                   IDX
SPD106


                  PD-9
          PROPELLER SHAFT                             PROPELLER SHAFT
           Inspection (Cont'd)
           q    Inspect journal axial play.
                If play exceeds the limit, replace propeller shaft assembly.
                    Journal axial play:
                        0.02 mm (0.0008 in) or less




 SPD874


           Disassembly
           CENTER BEARING
           1.   Place matching marks on flanges, then separate 2nd tube from
                1st tube.




 SPD109

           2.   Place matching marks on the flange and shaft.




 SPD110

           3.   Remove locking nut using Tool.
                  Tool number:
                      ST38060002 (J34311)
           4.   Remove companion flange using puller.




SPD170A

           5.   Remove center bearing using Tool and press.
                  Tool number: ST30031000 (J22912-01)




 SPD113


                   PD-10
         PROPELLER SHAFT                          PROPELLER SHAFT
          Disassembly (Cont'd)
          JOURNAL                                                          GI
          NOTE:
          1. Place matching marks on propeller shaft and flange or yoke.   MA

                                                                           EM

                                                                           LC
SPD128

          2.   Remove snap ring.                                           EC

                                                                           FE

                                                                           CL

                                                                           MT
APD011

          3.   Remove pushed out journal bearing by lightly tapping yoke AT
               with a hammer, taking care not to damage journal and yoke
               hole.
                                                                           TF

                                                                           PD

                                                                           FA
SPD732

          4. Remove bearing at opposite side in above operation. RA
          Put marks on disassembled parts so that they can be
          reinstalled in their original positions.
                                                                           BR

                                                                           ST

                                                                           RS
SPD131
                                                                           BT
          Assembly
          CENTER BEARING
                                                                           HA
          q    When installing center bearing, position the ``F'' mark on cen-
               ter bearing toward front of vehicle.
          q    Apply a coat of multi-purpose lithium grease containing EL
               molybdenum disulfide to the end face of the center bearing
               and both sides of the washer.
                                                                           IDX
SPD114


                  PD-11
         PROPELLER SHAFT                               PROPELLER SHAFT
          Assembly (Cont'd)
          q    Stake the nut. Always use new one.
          q    Align match marks when assembling tubes.




SPD117

          JOURNAL
          1. Assemble journal bearing. Apply recommended multi-purpose
             grease on bearing inner surface.
          When assembling, be careful that needle bearing does not fall
          down.




SPD133

          2.  Select snap ring that will provide specified play in axial direction
              of journal, and install them.
              Refer to SDS, PD-57.
          Select snap rings with a difference in thickness at both sides
          within 0.06 mm (0.0024 in).




APD012

          3.   Adjust thrust clearance between bearing and snap ring to zero
               by tapping yoke.




SPD732

          4.   Check to see that journal moves smoothly and check for axial
               play.
                  Axial play: 0.02 mm (0.0008 in) or less




SPD874


                  PD-12
    ON-VEHICLE SERVICE                                      FINAL DRIVE


         Front Oil Seal Replacement                                            GI
         (Front final drive: Model R200A)
         1.   Remove front propeller shaft.
         2.   Loosen drive pinion nut.                                         MA
                Tool number: ST38060002 (J34311)
                                                                               EM

                                                                               LC
SPD733

         3.   Remove companion flange.                                         EC

                                                                               FE

                                                                               CL

                                                                               MT
SPD734

         4.   Remove front oil seal.                                           AT

                                                                               TF

                                                                               PD

                                                                               FA
SPD735

         5.   Apply multi-purpose grease to cavity at sealing lips of oil seal. RA
              Press front oil seal into carrier.
                 Tool number:
                       KV38100500 (J25273)                                      BR
         6.   Install companion flange and drive pinion nut.
         7.   Install propeller shaft.
                                                                               ST

                                                                               RS
SPD736
                                                                               BT
         (Rear final drive: Model H233B)
         1.   Remove rear propeller shaft.
         2.   Loosen drive pinion nut.                                         HA
                Tool number: KV38104700 (J34311)

                                                                               EL

                                                                               IDX
 PD237


                 PD-13
    ON-VEHICLE SERVICE                   FINAL DRIVE
      Front Oil Seal Replacement (Cont'd)
         3.   Remove companion flange.




SPD737

         4.   Remove front oil seal.




SPD738

         5.   Apply multi-purpose grease to cavity at sealing lips of oil seal.
              Press front oil seal into carrier.
                 Tool number:
                       ST30720000 (J25405)
                       KV38102510 ( -- )
         6.   Install companion flange and drive pinion nut.
         7.   Install rear propeller shaft.




SPD739




                 PD-14
REMOVAL AND INSTALLATION (Front final drive)                          FINAL DRIVE


                 Removal                                                                   GI
                 1.   Remove front propeller shaft.
                 2.   Separate drive shaft from front final drive. Refer to FA section MA
                      [``Drive Shaft'', ``FRONT AXLE (4WD)''].
                 3.   Remove engine mounting bolts and raise up engine.
                 4.   Remove front final drive together with differential mounting EM
                      member.

                                                                                           LC
        SPD741


                 Installation                                                              EC
                 1.   Install front final drive assembly together with differential
                      mounting member.                                              FE

                                                                                           CL

                                                                                           MT
        SPD742

                 2.   Tighten front final drive securing bolts and nuts by following the   AT
                      procedure to prevent drive train vibration.
                 a.   Temporarily tighten nut A .
                 b.   Temporarily tighten nut B .                                          TF
                 c.   Tighten bolt C to the torque of 68 to 87 N m (6.9 to 8.9 kg-m,
                      50 to 64 ft-lb).
                 d.   Tighten bolt D to the torque of 68 to 87 N m (6.9 to 8.9 kg-m,       PD
                      50 to 64 ft-lb).
                 e.   Tighten nut A to the torque of 68 to 87 N m (6.9 to 8.9 kg-m,
                      50 to 64 ft-lb).                                                     FA
                 f.   Tighten nut B to the torque of 68 to 87 N m (6.9 to 8.9 kg-m,
                      50 to 64 ft-lb).
                 g.   Tighten nut E to the torque of 68 to 87 N m (6.9 to 8.9 kg-m,        RA
                      50 to 64 ft-lb).
                 3.   Install drive shaft. Refer to FA section [``Drive Shaft'', ``FRONT
                      AXLE (4WD)''].                                                       BR
                 4.   Install front propeller shaft.

                                                                                           ST

                                                                                           RS
        SPD743
                                                                                           BT

                                                                                           HA

                                                                                           EL

                                                                                           IDX


                         PD-15
REMOVAL AND INSTALLATION (Rear final drive)                        FINAL DRIVE


                 Removal
                 q   Remove propeller shaft.
                 Plug front end of transfer.
                 q   Remove axle shaft.
                     Refer to RA section (``REAR AXLE'').
                 CAUTION:
                 q   Be careful not to damage spline, sleeve yoke and front oil
                     seal when removing propeller shaft.
                 q   Before removing the final drive assembly or rear axle
                     assembly, disconnect the ABS sensor harness connector
                     from the assembly and move it away from the final drive/
                     rear axle assembly area. Failure to do so may result in the
                     sensor wires being damaged and the sensor becoming
                     inoperative.




                 Installation
                 q   Fill final drive with recommended gear oil.




        SPD123




                        PD-16
FRONT FINAL DRIVE   R200A


                              GI

                              MA

                              EM

                              LC

                              EC

                              FE

                              CL

                              MT

                              AT

                              TF

                              PD

                              FA

                              RA

                              BR

                              ST

                              RS

                              BT

                              HA

                              EL

                              IDX

                     APD020


      PD-17
             DISASSEMBLY                                          R200A


         Pre-inspection
         Before disassembling final drive, perform the following inspection.
         q   Total preload
         1) Turn drive pinion in both directions several times to set bear-
             ing rollers.
         2) Check total preload with Tool.
                Tool number: ST3127S000 (J25765-A)
                Total preload:
                     1.4 - 1.7 N m (14 - 17 kg-cm, 12 - 15 in-lb)

SPD664

         q    Ring gear to drive pinion backlash
              Check backlash of ring gear with a dial indicator at several
              points.
                 Ring gear-to-drive pinion backlash:
                      0.10 - 0.15 mm (0.0039 - 0.0059 in)




SPD513

         q    Ring gear runout
              Check runout of ring gear with a dial indicator.
                 Runout limit:
                     0.05 mm (0.0020 in)
         q    Tooth contact
              Check tooth contact. Refer to ADJUSTMENT (PD-30).




SPD524

         q    Side gear to pinion mate gear backlash
              Using a feeler gauge, measure clearance between side gear
              thrust washer and differential case.
                 Clearance between side gear thrust washer
                 and differential case:
                      Less than 0.15 mm (0.0059 in)




SPD665


         Final Drive Housing
         1.   Using three spacers [20 mm (0.79 in)], mount final drive
              assembly on Tool.
                 Tool number:
                     KV38100800 (J34310, J25604-01)




SPD666


                 PD-18
          DISASSEMBLY                                             R200A
         Final Drive Housing (Cont'd)
         2.   Remove differential side shaft assembly.                    GI

                                                                          MA

                                                                          EM

                                                                          LC
SPD644

         3.   Remove differential side flange.                            EC

                                                                          FE

                                                                          CL

                                                                          MT
SPD667

         4.  Put match marks on one side of side bearing cap with paint or AT
             punch to ensure that it is replaced in proper position during
             reassembly.
         Bearing caps are line-bored during manufacture and should TF
         be put back in their original places.
                                                                          PD

                                                                          FA
SPD526

         5.   Remove side bearing caps.                                   RA

                                                                          BR

                                                                          ST

                                                                          RS
 PD343

         6.   Remove differential case assembly with a pry bar.
                                                                          BT

                                                                          HA

                                                                          EL

                                                                          IDX
SPD668


                 PD-19
           DISASSEMBLY                                            R200A
          Final Drive Housing (Cont'd)
          Be careful to keep the side bearing outer races together with
          their respective inner cones -- don't mix them up.
          CAUTION:
          Side bearing spacer is placed on either the left or right
          depending upon final drive gear ratio. It should be labeled so
          that it may be replaced correctly.




 SPD527

          7.   Loosen drive pinion nut.
                 Tool number: ST38060002 (J34311)
          8.   Remove companion flange with puller.




SPD171A

          9.  Take out drive pinion together with rear bearing inner cone,
              drive pinion bearing spacer and pinion bearing adjusting
              washer.
          10. Remove front oil seal and pinion front bearing inner cone.




 SPD670

          11. Remove pinion bearing outer races with a brass drift.




  PD349

          12. Remove pinion rear bearing inner cone and drive pinion height
              adjusting washer.
                 Tool number: ST30031000 (J22912-01)




 SPD209


                 PD-20
           DISASSEMBLY                                              R200A


          Differential Case                                                   GI
          1. Remove side bearing inner cones.
          To prevent damage to bearing, engage puller jaws in grooves. MA
                Tool number:
                     A ST33051001 (J22888-20)
                     B ST33061000 (J8107-2)                            EM

                                                                              LC
SPD207A


          Be careful not to confuse the right and left hand parts.            EC
          Keep bearing and bearing race for each side together.
                                                                              FE

                                                                              CL

                                                                              MT
 SPD022

          2. Loosen ring gear bolts in a criss-cross pattern.                 AT
          3. Tap ring gear off the differential case with a soft hammer.
          Tap evenly all around to keep ring gear from binding.
                                                                              TF

                                                                              PD

                                                                              FA
 SPD024

          4.   Punch off pinion mate shaft lock pin from ring gear side.      RA

                                                                              BR

                                                                              ST

                                                                              RS
 SPD025
                                                                              BT
          Differential Side Shaft
          1.   Cut collar with cold chisel. Be careful not to damage differen-
               tial side shaft.                                                HA

                                                                              EL

                                                                              IDX
SPD236A


                  PD-21
          DISASSEMBLY                                               R200A
         Differential Side Shaft (Cont'd)
         2.   Reinstall differential side shaft into extension tube and secure
              with bolts. Remove rear axle bearing by drawing out differen-
              tial side shaft from rear axle bearing with puller.




SPD672

         3.   Remove grease seal and oil seal.




SPD647




SPD781




                 PD-22
                INSPECTION                                         R200A


           Ring Gear and Drive Pinion                                         GI
           Check gear teeth for scoring, cracking or chipping.
           If any damaged part is evident, replace ring gear and drive pinion MA
           as a set (hypoid gear set).

                                                                              EM

                                                                              LC


           Differential Case Assembly                                         EC
           Check mating surfaces of differential case, side gears, pinion mate
           gears, pinion mate shaft and thrust washers.                        FE

                                                                              CL

                                                                              MT
SPD097AA


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

                                                                              FA
  SPD715

                                                                              RA

                                                                              BR

                                                                              ST

                                                                              RS

                                                                              BT

                                                                              HA

                                                                              EL

                                                                              IDX


                   PD-23
          ADJUSTMENT                                                    R200A


         For quiet and reliable final drive operation, the following five adjust-
         ments must be made correctly:
         1. Side bearing preload
         2. Pinion gear height
         3. Pinion bearing preload
         4. Ring gear-to-pinion backlash. Refer to ASSEMBLY (PD-35).
         5. Ring and pinion gear tooth contact pattern




         Side Bearing Preload
         A selection of carrier side bearing adjusting washer is
         required for successful completion of this procedure.




         1.   Make sure all parts are clean and that the bearings are well
                                                   TM
              lubricated with light oil or ``DEXRON '' type automatic transmission
              fluid.
         2.   Place the differential carrier, with side bearings and bearing
              races installed, into the final drive housing.




SPD527

         3. Put the side bearing spacer in place.
         CAUTION:
         Side bearing spacer is placed on either the right or left
         depending upon final drive gear ratio. Be sure to replace it on
         the correct side.




SPD894

         4.   Using Tool, install original carrier side bearing preload shims
              on the carrier end, opposite the ring gear.
                 Tool number: KV38100600 (J25267)




SPD986


                   PD-24
           ADJUSTMENT                                                  R200A
          Side Bearing Preload (Cont'd)
          5.   Install the side bearing caps in their correct locations and GI
               torque the bearing cap retaining bolts.
                  Specification:
                       88 - 98 N m (9 - 10 kg-m, 65 - 72 ft-lb)             MA
          6.   Turn the carrier several times to seat the bearings.

                                                                                  EM

                                                                                  LC
 SPD526

          7.   Measure the turning torque of the carrier at the ring gear retain- EC
               ing bolts with a spring gauge, J8129.
                  Specification:
                       34.3 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb)                 FE
                       of pulling force at the ring gear bolt.

                                                                                  CL

                                                                                  MT
SPD194A

          8.   If the carrier turning torque is not within the specification range, AT
               increase or decrease the total thickness of the side bearing
               adjusting washers until the turning torque is correct. If the
               turning torque is less than the specified range, install washers TF
               of greater thickness; if the turning torque is greater than the
               specification, install thinner washers. See the SDS section for
               washer dimensions and part numbers.                                  PD
          9.   Record the total amount of washer thickness required for the
               correct carrier side bearing preload.
                                                                                  FA
 SPD772

          10. Remove the carrier from the final drive housing, saving the RA
              selected preload washers for later use during the assembly of
              the final drive unit.
                                                                                  BR

                                                                                  ST

                                                                                  RS
 SPD668
                                                                                  BT
          Pinion Gear Height and Pinion Bearing Preload
          1.   Make sure all parts are clean and that the bearings are well
               lubricated.                                                  HA
          2.   Assemble the pinion gear bearings into the pinion pre-load
               shim selector Tool, J34309.
                                                                                  EL

                                                                                  IDX
 SPD769


              



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