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Disassembly and Assembly
 
 
DISASSEMBLY
 
 
1. Remove pinion bearing assembly mounting bolts.
2. Lightly tap companion flange with a plastic hammer to remove pinion bearing assembly .
3. Remove the O-ring from pinion bearing assembly.
4. Remove drive pinion lock nut.
5. Remove drive pinion from pinion bearing assembly using drift (A) (commercial service tool) and separator (B) (commercial service tool).
6. Remove drive pinion adjusting shim.
7. Remove companion flange.
8. Remove dust shield.
9. Remove drive pinion oil seal.
10. Perform inspection after disassembly. Refer to Inspection.
 
 
ASSEMBLY
 
 
1. Select drive pinion adjusting shim. Refer to Adjustment.
2. Assemble the selected drive pinion adjusting shim to drive pinion.
3. Install the drive pinion to pinion bearing assembly using drift (commercial service tool).
caution
  • Never reuse pinion bearing assembly.
  • Apply transfer oil to pinion bearing part.
4. Install drive pinion oil seal to pinion bearing assembly using drift (A) (commercial service tool).
caution
  • Never reuse the oil seal.
  • When installing, never incline oil seal.
  • Apply multi-purpose grease onto oil seal lips, and transfer oil onto the circumference of the oil seal.
5. Install dust shield.
noteTighten dust shield together with pinion bearing assembly.
6. Install companion flange to pinion bearing using drift (A) (commercial service tool).
7. Tighten drive pinion lock nut within the limits of specified torque so as to keep the pinion bearing preload within the standard values.
(1) Apply anti-corrosive oil to the thread and seat of drive pinion lock nut and install it to drive pinion, and then tighten to the specified torque.
Drive pinion lock nut tightening torque: 90±9 N·m (9.2±0.92kg-m, 66±7 ft-lb)
caution
  • Never reuse drive pinion lock nut.
  • Check that drive pinion lock nut is seated on the companion flange.
(2) After tightening drive pinion lock nut to the specified torque, tighten the drive pinion lock nut additionally to the specified angle.
Drive pinion lock nut tightening angle: 25 degrees
(3) Measure the pinion bearing preload, using preload gauge [SST: ST3127S000 (J-25765-A)].
Pinion bearing preload: Refer to Preload Torque.
8. Install O-ring to pinion bearing assembly.
caution
  • Never reuse O-ring.
  • Apply multi-purpose grease lightly and evenly onto O-ring.
  • When installing O-ring, never use a tool.
  • Never damage O-ring.
9. Install pinion bearing assembly, and apply anti-corrosive oil onto thread and seats on the mounting bolts. Tighten to the specified torque.
noteTighten dust shield together with pinion bearing assembly.
10. Check backlash, tooth contact, total preload and companion flange runout. Refer to Adjustment.
cautionMeasure the total preload without oil seals of transfer cover and transfer case.