Z31 R200 Differential Service Manual
Contents
1. kg m ft Ib New parts 25 49 2 5 5 18 36 Wear limit of friction disc friction plate and spring plate mm 0 1 0 004 Allowable warpage of friction disc 0 08 0 0031 and friction plate mm in End play mm in 005 0 20 0 0020 0 0079 Friction plate Thickness mm in Part number 1 75 0 0689 1 85 0 0728 38432 N9000 38432 N9001 Friction disc Thickness mm in Part number 1 75 0 0689 38433 N9000 TIGHTENING TORQUE Unit kg m ft lb Differential case couple 8 11 08 11 5 8 8 0 screw PD 40 SPECIAL SERVICE TOOLS number Kent Moore No Tool Tool name T31520000 s o Drive pinion flange wrench KV38100800 Differential attachment Equivalent tool J25604 01 5705015000 426023 Engine stand D 5705011000 Engine stand 2 STO5012000 3 5730905000 Drive pinion rear inner race puller set D sT30031000 J22912 01 Puller 2 sT30901000 Base ST33068001 Diff side bearing puiler set D sT33051001 Body 2 ST33061000 J8107 2 Adapter Too number Kent Moore No Tool Tool name ST30611000 J25742 1 Drift C CO T30613000 25742 3 Drift T30621000 Drift KV38100200 Gear carrier side oil seal drift KV38100500 Gear carrier front oil seal drift ST33290001 J25810 A2. PROPELLER SHAFT amp DIFFERENTIAL CARRIER SECTION P D Search CONTENTS PROPELLER SHAFT 2 5 Eos er eb b pa E n ERG Ra PD 2 FINAL DRIVE Model R200 PD 4 ON VEHICLE SERVICE Model 200 PD 5 REMOVAL AND INSTALLATION Model R200 PD 7 DISASSEMBLY Model R200 PD 8 INSPECTION Model 200 PD 13 ADJUSTMENT Model R200 PD 14 ASSEMBLY Model 200 PD 24 LIMITED SLIP DIFFERENTIAL Model R200 PD 30 SERVICE DATA AND SPECIFICATIONS 5 0 5 PD 38 SPECIAL SERVICE TOOLS PROPELLER SHAFT Companion flange 0 39 44 4 0 4 5 kgm 29 33 ft lb Propeller shaft Sleeve yoke PD427 General Inspection Inspect propeller shaft tube surface for dents or cracks If damaged replace propeller shaft assembly e f center bearing is noisy or damaged replace center bearing PROPELLER SHAFT VIBRATION To check and correct an unbalanced propeller shaft proceed as follows 1 Remove undercoating and other foreign material which could upset shaft balance and check shaft vibration by road te
3. 99 E a oa 5 uoluld 3 Bunsnfpe Q 6587 zx 195 Igpou 30 5A isnuu Eo 5 o 1 8 828 I apis J8uu 9284 OL 9 zi d T WN 86 68 QU gee OS 1jeUS ISNIYI apis 4 05 AS 3 3 uotutd 1 Bunsn pe apis Jeioads 48416919 2 5 apis 91 vz 91 rj dij amp ujjees 48 89 0 21 06 BLL 88 0 lees epis PD 4 ON VEHICLE SERVICE Model R200 Front Oil Seal Replacement 1 Remove propeller shaft 2 Loosen drive pinion nut SPD517 Tool number ST31520000 3 Remove companion flange SPD518 SPD519 Tool number ST33290001 J25810 A 5 Apply multi purpose grease to cavity at sealing lips of oil seal Press front oil seal into carrier SPD520 Tool number KV38100500 6 Install companion flange and drive pinion nut 7 Install propeller shaft PD 5 ON VEHICLE SERVICE Model R200
4. 2871A 2 Sleeve type 71 2 80 Shell type non disassernbly type 665 26 18 685 26 97 665 26 18 685 26 97 865 34 06 885 34 84 B85 34 84 75 2 95 TIGHTENING TORQUE Unit Nem kg m ft lb Shaft to companion 39 44 4 0 4 5 29 33 flange bolts SERVICE DATA Final drive model R200 Drive pinion bearing preload adjusting method Adjusting spacer and washer Drive pinion preload With front oil seal kg cm in Ib 1 13 1 72 11 5 17 5 10 0 15 2 Drive pinion preload Without front oil seal kg cm in Ib 1 0 1 3 10 13 8 7 11 3 1 23 2 30 12 5 23 5 10 9 20 4 Total preload N m kg cm in Ib Side bearing adjusting method Shim Backlash Drive pinion to ring gear 0 13 0 18 0 0051 0 0071 Side gear to pinion mate gear Clearance between side gear to differential case mm in 0 10 0 20 0 0039 0 0079 Ring gear runout timit mm in 0 05 0 0020 PD 38 SERVICE DATA AND SPECIFICATIONS 5 0 5 Pinion height adjusting washer Thickness mm in 3 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 0 05 0 0020 0 07 0 0028 Urive pinion b
5. Side bearing outer race puller KV38100300 J25523 Diff side bearing drift KV38100401 Pilot bearing drift KV38100600 J25267 Side bearing spacer drift HT72400000 Slide hammer Tool number Kent Moore name ST3127S000 See J25765 A Preload gauge D GG91030000 J25765 A Torque wrench 0 HT62940000 Socket adapter 8 HT62900000 Socket adapter J8001 M Metric dial indicator set J8001 6 dial indicator only J25269 B Pinion height amp preload gauge set D J25269 23 Bolt amp nut 2 J23597 1 Arbor Long plunger Use with J23597 1 J25269 1 Gauge plate 25269 2 Rear pinion bearing pilot J25269 3 Front pinion bearing pilot J25269 4 Side bearing discs 2 Req d SPECIAL SERVICE TOOLS Tool number Kent Moore No Tool Too name J25269 25 Lead preload washers Pkg of 5 J25269 26 Bearing preload adapter J25269 29 Front bearing pilot support J25269 32 Instructions J25407 01 Side bearing measuring set consists of D J25407 1 4 step gauge block 2 J25407 2 Base plate 3 J25407 3 Weight block 26099 Differential shim organizer J26335 Differential filler plug wrench KV381051S0 X34292 Rear axle shaft dummy 1 KV38105110 Torque wrench side KV38105120 Vise side 2
6. Side Oil Seal Replacement Ring Gear to Drive Pinion Backlash 1 Remove drive shafts Refer to section RA 2 Remove oil seal Support carrier with a jack Remove rear cover 3 Check ring gear to drive pinion backlash with a dial indicator at several points If it is not within specifications adjust it after re moving final drive assembly 2 ha I SPD521 3 Apply multi purpose grease to cavity at sealing lips of oil seal Press fit oil seal into carrier C Dial m indicator SPD523 SPD522 Tool number KV38100200 4 Install drive shafts PD 6 REMOVAL AND INSTALLATION Model R200 Removal Installation e Full final drive with recommended gear oil Refer to section Gl e Remove propeller shaft Refer to Propeller Shaft e Remove drive shafts Refer to RA section Pull off differential carrier backward to gether with jack Filler opening SPD348 SPD511 CAUTION Be careful not to damage spline and sleeve yoke when removing propeller shaft After carrier assembly is removed support suspension member on a stand to prevent its insulators being twisted or damaged PD 7 DISASSEMBLY Model R200 Before disassembling final drive perform the following inspection e Total preload 1 Turn drive pinion in both directions several times to set bearing rollers 2 C
7. in pressure ring with flat surfaces facing up and down SPD483 Install differential case A on differential case B Align cases by their match marks then install screws while pushing differential case down with a press Press 5733061000 J8107 2 Matching p mark SPD507 Assembly Cont d After assembly measure differential torque If it is not within the specification adjust it by selecting friction disc Refer to 5 0 5 KV38105150 34292 5 0620 Differential torque New parts 25 49 N m 2 5 5 kg m 18 36 ft lb PD 37 SERVICE DATA AND SPECIFICATIONS 5 0 5 GENERAL SPECIFICATIONS 2 seater Applied model M T AIT Propeller shaft model Number of joints Coupling method with transmission Distance between yokes Type of journal bearing Shaft length Spider to spider Shaft outer diameter SERVICE DATA Unit mm in Mode 2571 Propeller shaft runout timit 0 6 0 024 Journal axial play 0 0 GENERAL SPECIFICATIONS VG30E without turbo VGS0E turbo Applied model Fina drive model Ring gear pitch diameter 200 7 87 mm in Gear ratio Number of teeth Ring gear Drive pinion Oil capacity approx 1 8 2 US pt Imp pt 1 8 3 7 8 3 1 8 Propeller Shaft VG30E without turbo VG30E turbo VG30E without turbo Differential Carrier 2 2 seater VG30E turbo
8. 04 2 25 0 0886 38453 N3105 2 30 0 0906 38453 N3106 2 35 0 0925 38453 N3107 2 40 0 0945 38453 N3108 2 45 0 0965 38453 N3109 2 50 0 0984 38453 N3110 2 55 0 1004 38453 N3111 2 60 0 1024 38453 N3112 Side gear thrust washer Thickness mm in Part No 0 75 0 80 0 0295 0 0315 38424 N3100 0 80 0 85 0 0315 0 0335 38424 N3101 0 85 0 90 0 0335 0 0354 38424 N3102 0 90 0 95 0 0354 0 0374 38424 N3103 TIGHTENING TORQUE Type R200 Unit kg m ft lb Final drive installation Drive shaft to rear axle VG30E without 39 49 4 5 29 36 turbo VG30E turbo 59 69 6 7 43 51 Rear cover to 88 118 9 0 120 65 87 mounting insulator Mounting insulator to body Bolt 29 39 3 4 22 29 59 78 6 8 43 58 Differential carrier to 59 78 6 8 43 58 suspension member Final drive assembly Drive pinion nut 186 294 19 30 137 217 Ring gear bolt using 132 152 13 5 15 5 98 112 Locktite stud lock or equivalent Side bearing cap bolt 88 98 9 0 10 0 65 72 Rear cover fixing bolt 16 24 16 2 4 12 17 Companion flange to 39 44 4 0 4 5 29 33 propeller shaft fixing bolt Filler and drain plug 59 98 6 10 43 72 PD 39 SERVICE DATA AND SPECIFICATIONS S D S Final Drive SERVICE DATA Differential torque on vehicle N m kg m ft lb New parts 49 118 5 12 36 87 Used parts 29 88 3 9 22 65 Differential torque
9. 200 Side Bearing Preload 1 To simplify the job make a chart like the one C amp D Figures marked on differential case below to organize your calculations A Lefthousig f ren eom o owe en NN PD359 F Right side bearing H or ring gear G Spacer measurement 2 Write the following numbers down in the chart A amp B Figures marked on gear carrier SPDS76 G This is the difference in thickness of side spacer against standard width 8 10 mm 0 3189 in G Standard spacer Measured spacer PD358 SPD544 PD 18 ADJUSTMENT Model R200 3 Measure how far under the standard thickness 21 mm 0 83 in the side bearings are It will require the tools shown below 5 0545 Tool number 4 step gauge block J25407 1 Base plate J25407 2 Weight block J25407 3 4 Set weight block 4 step gauge block 21 mm 0 83 in and dial indicator on base plate 5 Adjust dial indicator scale to zero SPD546 6 Carefully slide 4 step gauge block and weight block out from under dial indicator 7 Lubricate side bearing and place side bearing on base plat Side Bearing Preload Cont d Make sure that base plate has a recess in it and that bearing will turn freely when positioned over the recess as shown Side bearing inner race Side bearing outer race SS Y a N 1 Be
10. aring NH U T thickness L Ni A measurement Recessed surface plate SPD547 8 Place weight block on side bearing 9 Slide dial indicator on weight block SPD548 PD 19 ADJUSTMENT Model R200 Side Bearing Preload Cont d 10 Turn weight block a few times to ensure that bearing is properly seated 11 Read dial indicator e Normal indication 0 10 0 30 mm 0 0039 0 0118 in If the needle fluctuates erratically then bearing is either dirty or defective and should be cleaned or replaced 5 0549 12 Measure both bearings in the same way and write the left side bearing measurement next to E and the right side bearing measurement next to F 13 Calculate washer thickness following the charts below Left ring gear side OPERATION Left side standard number Enter A factor gear carrier DIFFERENCE Enter factor s sign O LINE PLUS SIGN Line 91 SUBTRACT Line 8L 7L Enter difference on Line 101 MINUS SIGN Line 9L ADD Lines 7L and 81 Enter sum on Line 10L Left side shim size PD 20 ADJUSTMENT Model R200 Right side LINE OPERATION o EN Right side standard number 1 95 Enter B factor gear carrier Enter factor right bearing Enter G factor 200 only See Chart Below ADD Lines 1R 2R 3R and 4R Enter SUM Enter D fact
11. ars and pressure rings so that they New parts 25 49 can be reinstalled in their original positions 2 5 5 kg m 18 36 ft lb PD 33 LIMITED SLIP DIFFERENTIAL Model R200 Inspection and Adjustment CONTACT SURFACES DISC AND PLATE e Clean the disassembled parts with suitable Clean the discs and plates with suitable solvent solvent and blow dry with compressed air and blow dry with compressed air e f following surfaces are found with burrs or e Inspect discs and plates for wear nicks and scratches smooth with oil stone burrs 1 Differential case 2 Differential case B 3 Pressure ring 4 Pinion mate shaft 5 6 Pinion mate gear Side gear SPD478 e To test if friction disc or plate is not distored place it on a surface plate and rotate it by hand with indicating finger of dial gauge resting against disc or plate surface If it exceeds limits replce with a new plate SPD621 SPD622 Allowable warpage 0 08 mm 0 0031 in PD 34 LIMITED SLIP DIFFERENTIAL Model R200 Inspection and Adjustment Cont d e In order to determine if the wear limit has been CLUTCH PLATES END PLAY exceeded for each friction disc friction plate 1 Determine dimension A with following and spring plate subtract the thickness of pro equation jected portions from the thickness of frictional A C DtE surface If wear of any of the part exceeds the limit replace with a new one For friction plate choose ne
12. dapter J25269 26 SPD531 3 Install these parts into gear carrier 4 Stand front bearing pilot support on the bench with the appropriate side up and as semble front pinion bearing pilot front pinion bearing inner race and lead preload washer Ensure that all parts are seated HN Pinion front bearing inner race Setting Up Each Tool Set up each tool rear pinion bearing and front pinion bearing before adjusting pinion height and drive pinion bearing preload 1 Install rear pinion bearing pilot into gauge plate and slide over hex head long bolt SPD534 Tool number Spee Lead preload washer Tool number J25269 25 head long bolt J25269 23 Front pinion bearing pilot Gauge plate J25269 1 J25269 3 Rear pinion bearing pilot J25269 2 Front bearing pilot support J25269 29 PD 14 ADJUSTMENT Model R200 Setting Up Each Tool Cont d Drive Pinion Height 1 Install two side bearing discs with arbor assembly Ensure that arbor turns freely 5 Holding these parts together slide the as sembly over hex head long boit into gear carrier Install support nut Finger tighten the nut and ensure that all parts turn freely and are properly aligned 5 0537 Tool number Arbor assembly J23597 1 Side bearing disc 25269 4 SPD535 6 Tighten support nut carefully to correct pre load of 0 6 to 1 0 N m 6 to 10 kg cm 5 2 t
13. e pinion bearing preload disas semble pinion height bearing preload tools and measure thickness of lead washer This is the correct size pinion bearing adjusting washer required 8 Calculate washer thickness following the chart below ENL T NN a prenens eee mro _ H factor sign PLUS SIGN line 5 SUBTRACT line 4 if a lead washer is not available use piece of thick roll solder to obtain preload washer size from 3 Enter difference on line 6 MINUS SIGN 5 line 5 ADD lines 3 and 4 Enter sum on line 6 Example Dial Indicator Reading 0 3 mm SPD543 Number on Pinion Head 2 Select the proper washer Refer to S D S 3 00 standard measure If you cannot find shims with the desired 0 3 indicator reading thickness use shims so that the total thickness is the closest to the calculated value Sometimes the correct dimension cannot be set with washers alone In these cases washers may be used in combination with drive pinion bearing adjusting spacers Refer to S D S 3 3 Pinion head is plus so you 0 02 SUBTRACT it 3 28 mm total pinion washer you wil need 9 Select the proper washer Refer to S D S If you cannot find the desired thickness of washer use washer so that thickness is the closest to the calculated value Example 3 28 mm Calculated total pinion washer in step 8 The correct washer is 3 27 mm Part number 38154 P6023 PD 17 ADJUSTMENT Model R
14. earing preload adjusting washer Thickness mm in 3 80 3 82 0 1496 0 1504 3 82 3 84 0 1504 0 1512 3 84 3 86 0 1512 0 1520 3 86 3 88 0 1520 0 1528 3 88 3 90 0 1528 0 1535 3 90 3 92 0 1535 0 1543 3 92 3 94 0 1543 0 1551 3 94 3 96 0 1551 0 1559 3 96 3 98 0 1559 0 1567 3 98 4 00 0 1567 0 1575 4 00 4 02 0 1575 0 1583 4 02 4 04 0 1583 0 1591 4 04 4 06 0 1591 0 1598 4 06 4 08 0 1598 0 1606 4 08 4 10 0 1606 0 1614 Drive pinion bearing preload adjusting spacer Length mm in 55 10 2 1693 55 40 2 1811 55 70 2 1929 56 00 2 2047 56 25 2 2146 Part No 38154 P6017 38154 P6018 38154 P6019 38154 P6020 38154 P6021 38154 P6022 38154 P6023 38154 P6024 38154 P6025 38154 P6026 38154 P6027 38154 P6028 38154 P6029 38154 P6030 38154 P6031 38154 P6032 38154 P6033 38154 P6034 38154 P6035 38154 P6036 38453 28500 38454 28500 Part No 38125 61001 38126 61001 38127 61001 38128 61001 38129 61001 38130 61001 38131 61001 38132 61001 38133 61001 38134 61001 38135 61001 38136 61001 38137 61001 38138 61001 38139 61001 Part No 38165 B4002 38165 B4003 38165 B4004 38165 61001 38166 61001 Differential Carrier Cont d Side bearing adjusting washer Thickness mm in Part No 2 00 0 0787 38453 N3100 2 05 0 0807 38453 N3101 2 10 0 0827 38453 N3102 2 15 0 0846 38453 N3103 2 20 0 0866 38453 N31
15. earing spacer Front pilot bearing SPD556 5 Apply multi purpose grease to cavity at sealing lips of oil seal Install front oil seal SPD557 Tool number KV38100500 6 Install companion flange and tighten pinion nut to specified torque Ascertain that threaded portion of drive pinion and pinion nut are free from oil or grease PD466 Tool number ST31520000 PD 26 ASSEMBLY Model R200 7 Turn drive pinion in both directions several times and measure pinion bearing preload PD340 Tool number 5131275000 See 25765 Pinion bearing preload With front oil seal 1 13 1 72 11 5 17 5 kg cm 10 0 15 2 in Ib When pinion bearing preload is outside the specifications replace pinion bearing adjusting washer and spacer with a different thickness 8 Select side bearing adjusting washer Refer to Adjustment 9 Install differential case assembly with side bearing outer races into gear carrier SPO527 Differential Carrier Cont d 10 Insert left and right side bearing adjusting washers in place between side bearings and carrier SPD558 11 Drive in side bearing spacer with Tool Side bearing spacer SPD559 Tool number KV38100600 J25267 PD 27 ASSEMBLY Model R200 Differential Carrier Cont d 12 Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier 14 Measure
16. g m 22 65 ft lb L Length of torque wrench SPD822 Used parts ft Ib kg m 2 5 57 15 mm 2 2500 in SPD820 i204 05 07 09 10 15 20 25 30 ft L Length of torque wrench SPO823 CHECK Limited slip differential identification Lift both rear wheels off ground Turn one rear wheel by hand 3 If both rear wheels turn in the same direction simultaneously vehicle is equipped with limited slip differential N PD 32 LIMITED SLIP DIFFERENTIAL Model R200 Pay attention to direction of parts and assembly procedures Differential case couple het Spacer When pressed with a press Differential case Friction plate 0 8 11 0 8 1 1 5 8 8 0 M disc Spring plate D L Differential case D Pinion mate shaft B 8 L Friction disc Pressure ring AD 9 d Side gear gh Pinion mate gear S NY Differential case A Spring plate Friction plate O kg m ft lb r Pay attention to its direction SPD813 Disassembly 1 Prior to disassembly measure differential tor 2 Loosen screws on differential cases A and B que and record it as a reference using a press Press ST33061000 J8107 2 Matching mark KV381051S0 X34292 EE SPD507 3 Separate differential case A and B Draw out 6 0 component parts discs and plates Differential torque Put marks on ge
17. heck total preload with Tool PD245 Tool number ST3127S000 See 25765 Total preload 1 23 2 30 N m 12 5 23 5 kg cm 10 9 20 4 in Ib e Ring gear to drive pinion backlash Check backlash of ring gear with a dial indi cator at several points SPD513 Ring gear to drive pinion backlash 0 13 0 18 mm 0 0051 0 0071 in Pre inspection e Ring gear runout Check runout of ring gear with a dial indi cator SPD524 Runout limit 0 05 mm 0 0020 in e Tooth contact Check tooth contact referring to Adjustment e Side gear to pinion mate gear backlash Measure clearance between side gear thrust washer and differential case with thickness gauge SPD370 Clearance between side gear thrust washer and differential case Less than 0 15 mm 0 0059 in PD 8 DISASSEMBLY Model R200 Differential Carrier 1 Using three spacers 45 mm 1 77 mount 3 Remove side bearing caps carrier on Tool PD343 SPD525 Tool number KV38100800 J25604 1 4 Using Tool lift differential case assembly out 2 Put match marks on one side of side bearing cap and gear carrier with paint or punch to en sure that it is replaced in proper position during reassembly Bearing caps are line board during manufacture and should be put back in their original places PD344 Tool number HT72400000 Be careful to keep the side bearing outer races together
18. ift Be careful of its direction SEDEM Punched mark 16 Recheck ring gear to drive pinion backlash because increase or decrease in thickness of Front shims will cause change of ring gear to pinion 5 0825 backlash 17 Check runout of ring gear with a dial indicator SPD524 Runout limit 0 05 mm 0 0020 in e f backlash varies excessively in different places the variance may have resulted from foreign matter caught between the ring gear and the differential case PD 29 LIMITED SLIP DIFFERENTIAL Model R200 Trouble shooting and diagnoses Customer complaint Final drive has high pitched chattering noise during turning maneuvers Change differential gear oil to the recommended oil Is chattering noise still evident when driving vehicle in Explain that slight chattering noise may occur for approx 100 km 62 miles after changing oil It is not a problem Check if differential torque is within specified range biefins di Refer to CHECK NG Disassemble final drive and check parts tight circles 5 clockwise and 5 counterclockwise E a O K isassemble final drive and replace Jimi i Perform road test and check noise level Dites ted slip N G differential assembly Explain that slight chattering noise may occur for approx 100 km 62 miles after changing oil It is not a problem PD 30 LIMITED SLIP DIFFERENTIAL Model R200 Tro
19. l case on ring gear SPD600 7 Apply locking agent Locktite stud lock or equivalent to ring gear bolts and install them Tighten bolts in a criss cross fashion lightly tap ping bolt head with a hammer 8 Press fit side bearing inner races on differential case with Tool PD353 Tool number KV38100300 J25523 5733061000 J8107 2 Differential Carrier 1 Press fit front and rear bearing outer races with Tools RQ Pinion front bearing outer race Pinion rear bearing outer race p SS e Sas 7 2 2 2 ry 2 2 2 2 PSS SPD555 Tool number ST30611000 J25742 1 ST30621000 ST30613000 J25742 3 PD 25 ASSEMBLY Model R200 Differential Carrier 2 Select pinion height adjusting washer and pinion bearing adjusting washer spacer refer ring to Adjustment 3 Install pinion height adjusting washer in drive pinion and press fit rear bearing inner race in it with press and Tool Press Adjusting SPD377 Tool number ST30901000 4 Set drive pinion assembly as shown in figure below in differential carrier and install drive pinion with press and suitable tool Stop when drive pinion touches bearing Suitable spacer 7 Drive pinion Pinion bearing adjusting spacer Pinion bearing adjusting washer Aa Pinion front bearing inner race QT Front pilot b
20. ll be correct if you have calculated the shims correctly and the backlash is correct However in extremely rare cases you will have to use trial and error processes until you get a good tooth contact pattern The tooth pattern is the best indication of how well a differential has been set up Toe contact Flank contact Y bs i m To correct reduce thickness of pinion height adjusting washer in order to make drive pinion go away from ring gear 2 7 5 0007 23 ASSEMBLY Model R200 Differential Case 1 Install side gears pinion mate gears thrust Clearance between side gear thrust washer and washers and thrust block into differential differential case case 0 10 0 20 mm 0 0039 0 0079 in 4 Install pinion mate shaft lock pin with a punch punch Make sure lock pin is flush with case SPD552 2 Fit pinion mate shaft to differential case so that it meets lock pin holes SPDOS3O 5 Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly SPO553 3 Adjust clearance between rear face of side gear and thrust washer by selecting side gear thrust washer Refer to S D S et SPD322 Feeler gauge 5 0029 PD 24 ASSEMBLY Model R200 Differential Case Cont d 6 Apply locking agent Locktite stud lock or equivalent to contacting surfaces of ring gear and differential case then place differentia
21. o 8 7 in Ib 2 Place side bearing discs with arbor assembly into differential carrier Lift spring loaded plunger and place it on the face of gauge plate Spring loaded 2 122 E cm NM 2 SPO536 2 7 22 Tool number J25765 A 5 0538 PD 15 ADJUSTMENT Model R200 3 Install bearing caps 4 Install dial indicator and tighten hold down clamp Spring loaded plunger compressed SPD539 Tool number Hold down clamp J8001 1 Dial indicator clamp J8001 2 Dial indicator 98001 6 5 To zero dial indicator rotate arbor and plunger back and forth and note highest deflection the point where needle changes direction Set dial indicator at zero SPD540 Drive Pinion Height Cont d 6 Rotate gauge plate until the plunger falls off gauge plate and read dial indicator Read the dial indicator diectly Repeat to ensure accuracy Spring loaded plunger extended 1 NS E 1 a Ad mta tar DA Gauge plate rotated 180 5 0541 7 Read head number on drive pinion head The figure for H is a dimensional variation in units of 0 01 mm 0 0004 in against a standard measurement Head number SP D542 PD 16 ADJUSTMENT Model R200 Drive Pinion Height Cont d Drive Pinion Preload To determin
22. or differential case Wu 7R SUBTRACT Line 6R from 5R Enter DIFFERENCE Enter factor ring gear mE Enter factor s sign O PLUS SIGN Line 9R ADD Lines 7R and 88 Enter sum on Line 10R MINUS SIGN Line 88 from 78 Enter difference on line 10R Right side shim size T Line 9R SUBTRACT G FACTOR CALCULATION R200 ONLY Side bearing spacer Standard size 8 10 ce _ C SUBTRACT Line B from Line A and enter DIFFERENCE on Line 4R of right side of chart Side Bearing Preload Cont d The formulas are as follows T 2 05 mm B D F G H 1 95 mm Example Left Side T1 Right Side T2 The measurement for the shim pack on the left 1 should be 2 28 mm and for the right 2 2 14 mm To check the accuracy of your work in the previous step the side bearing shim measure ment should be figured with a Side Bearing Shim Calculator PD 21 ADJUSTMENT Model R200 Side Bearing Preload Cont d Follow the instructions for the sample given below EXAMPLE CALCULATOR Left Side Step 1 Move slide 1 to place C 3 in line with an arrow Step 2 Move slide 2 to place D3 in line with C 3 Step 3 Move slide 3 to place E 18 in line with 2 Over Slanderd 212 1 614 6104 04 Step 4 Read answer at left side arrow 2 28mm or close
23. ring gear to drive pinion backlash with a dial indicator be 2 SPD526 SPD513 Ring gear to drive pinion backlash 0 13 0 18 mm 0 0051 0 0071 in 13 Apply multi purpose grease to cavity at sealing lips of oil seal Install side oil seal If backlash is too small decrease thickness of right shim and increase thickness of left shim by the same amount If backlash is too great reverse the above pro cedure Never change the total amount of shims as it will change the bearing preload 15 Check total preload with Tool When checking preload turn drive pinion in both directions several times to set bearing rollers SPD560 Tool number KV38100200 PD340 Tool number ST3127S000 See J25765 A Total preload 1 23 2 30 12 5 23 5 kg cm 10 9 20 4 in Ib PD 28 ASSEMBLY Model R200 Differential Carrier Cont d e f preload is too great add the same amount of e f the backlash varies greatly when the runout shim to each side of the ring gear is within a specified range the e f preload is too small remove the same hypoid gear set or differential case should be amount of shim to each side replaced Never add or remove a different number of shims 18 Check tooth contact for each side as it will change ring gear to drive Refer to Adjustment pinion backlash 19 Install rear cover and gasket 20 Drive breather into gear carrier evenly with brass dr
24. rom ring gear side Lock pin is calked at pin hole mouth on differen tial case SPD025 PD 12 INSPECTION Model R200 Ring Gear and Drive Pinion Bearing 1 Thoroughly clean bearing and dry with com pressed air 2 Check bearings for wear scratches pitching or flaking Check tapered roller bearing for a burned out portion as shown in the figure below If dam aged replace outer and inner races as a set Check gear teeth for scoring cracking or chipping If any damaged part is evident replace ring gear and drive pinion as a set hypoid gear set Differential Case Assembly ____ Check mating surfaces of differential case side gears pinion mate gears pinion mate shaft thrust block and thrust washers Particular point tube checked SPO458 SPD584 PD 13 ADJUSTMENT Model R200 2 Slide pinion rear bearing inner race bearing preload adapter and pinion bearing adjusting spacer over hex head long bolt To avoid any confusion while calculating bearing shims it is absolutely necessary to stay with the metric system If you measure anything in inches the results MUST be converted to the metric system You can use a conversion chart or a calculator as illustrated Tool Pinion rear bearing inner race think metric CONVERTER tu Pinion bearing adjusting spacer SPD533 Tool number Bearing preload a
25. st 2 f shaft vibration is noted during road test disconnect propeller shaft at differential 3 Again check shaft vibration If vibration carrier companion flange rotate companion still persists replace propeller shaft assembly flange 180 degrees and reconnect propeller shaft SPD102 PD 2 PROPELLER SHAFT Removal and Installation Inspection e Put match marks on flanges and separate propeller shaft from differential carrier Inspect propeller shaft runout If runout exceeds specifications replace propeller shaft assembly SPD106 SPD103 Runout limit 0 6 mm 0 024 in e Inspect journal axial play If the play exceeds specifications replace propeller shaft assembly e Draw out propeller shaft from transmission and plug up rear end of transmission rear extension housing Journal axial play 0 mm 0 in Transmission SPD359 PD 3 FINAL DRIVE Model R200 10 320 pnis 831394907 Guryoo 4 peainbea s juawasnipy xx pa quuessesip a2ejdaJ q SPD516 142 LEL 61 762 981 t amp Bue 5 dij Surees 1895 1010014 10119 31024 182eds 1019 u04 1004 uoluld EE 8281 we wu E Y c J YSEM ZLL 86 99 SEL 291 ZEL
26. to 087 in 5 0550 Right Side Step 1 Move slide 1 to place B 3 in line with an arrow Step 2 Move slide 2 to place G7 in line with D 3 Step 3 Move slide 3 to place F 14 in line with H 2 red scale for right side Step 4 Read answer at right side arrow 2 14mm or closer to 086 in SPD551 14 Compare these answers with the answers on the previous page If both answers agree pro ceed to the next step 15 Select the proper washer Refer to S D S If you cannot find the desired thickness of washer use washer so that thickness is the closest to the calculated value PD 22 ADJUSTMENT Model R200 Gear tooth contact pattern check is necessary to verify correct relationship between ring gear and drive pinion Hypoid gear set which are not positioned properly may be noisy or have short life or both With a pattern check the most desirable contact for low noise level and long life can be assured 1 Thoroughly clean ring gear and drive pinion teeth 2 Sparingly apply a mixture of powdered ferric oxide and oil or equivalent to 3 or 4 teeth of ring gear drive side 2 twee gt SPD357 Face contact Heel contact b ae To correct increase thickness of pinion height adjusting washer in order to bring drive pinion close to ring gear Tooth Contact 3 Hold companion flange steady by hand and rotate the ring gear in both directions 5 0308 Usually the pattern wi
27. uble shooting and diagnoses Cont d Customer complaint Rear wheels slip and remain stuck in mud or on snowy roads Check if vehicle has limited slip differential Explain that vehicle does not have limited slip Refer to CHECK No differential Yes Explain that purpose of limited slip differential is to improve cornering performance but rear wheels may stip or get stuck in mud or on snowy roads D mble final drive and check parts Refer to CHECK NG isassemble final dri check parts Disassemble final drive and replace timited slip differentia assembly Explain that slight chattering noise may occur for approx 100 km 62 miles after changing oil It is not a problem PD 31 LIMITED SLIP DIFFERENTIAL R200 Trouble shooting and diagnoses Cont d CHECK Check differential torque New parts 1 Drive vehicle enough to warm up differentia ft lb oil 100 137 2 Lift both rear wheels ground 18 too 3 Shift transmission gear into 1st M T model or 12 LEE P range A T model 98 10 4 Release parking brake 5 60 7g 5 Check differential torque at wheel stud bolt 8 Differential torque on vehicle 40 el New parts 39 20 5 12 kg m 36 87 ft lb 204 05 06 07 08 10 Used parts ee 1 56 2 0 29 88 25 3 0 it 3 9 k
28. w one whose thickness is closest to old one s thickest figure SPD817 Measuring points A Projected portion B Frictional surface Wear limit SPD403 imi 2 Measure di HR Wear limit asure distance 0 1 mm 0 004 in 5 18 5 LIMITED SLIP DIFFERENTIAL Model R200 Inspection and Adjustment Cont d 3 Measure thickness of each side of spring plates L Right side L Left side Li 4 eee ee SPD814 4 Measure thickness of each side of friction plates friction disc and spacer K Right side Left side SPD815 5 Determine dimension M with following equations M L L K 6 Determine end play P with following equa tion P A F M End play 0 05 0 20 mm 0 0020 0 0079 in 7 f not within specification select discs and plates to adjust correctly Assembly e As an aid to installation apply sufficient amounts of recommended L S D gear oil Refer to MA section to the faces of pressure rings discs and plates to be assembled together SPD479 e Install spring plates friction plates and friction discs Pay particular attention to the direction of clutch plates and their assembly sequence Friction plate Friction disc 7 T lt Spacer SPD623 PD 36 LIMITED SLIP DIFFERENTIAL Model R200 Always attach pinion mate shaft to V groove
29. with inner race do not mix them up SPD526 5 0527 PD 9 DISASSEMBLY Model R200 Differential Carrier Cont d 7 Remove oil seal 8 Remove pilot bearing together with pilot bearing spacer and front bearing inner race with Tool 5 Loosen drive pinion nut and pull off com panion flange PD345 22 ATTIRE AA rrr Z PD346 6 Take out drive pinion together with rear bearing inner bearing spacer and justing washer Tool number KV38100401 9 Remove side oil seal 10 Remove pinion bearing outer races with a brass SPD528 PD 10 DISASSEMBLY Model R200 Differential Carrier Cont d Differential Case 1 Remove side bearing inner races To prevent damage to bearing engage puller paws with grooves 11 Remove pinion rear bearing inner race and pinion height adjusting washer PD179 Tool number 5730031000 J22912 01 SPD529 Tool number ST33051001 ST33061000 J8107 2 Be careful not to confuse the right and left hand parts 5 0022 11 DISASSEMBLY Model R200 Differential Case Cont d 2 Loosen ring gear bolts in a criss cross fashion 3 Tap ring gear off the gear case with a soft hammer Tap all around to keep ring gear from binding 5 0024 4 Punch off pinion mate shaft lock pin f
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