REAR FINAL DRIVE

D DRIVELINE/AXLE

SECTION RFD
REAR FINAL DRIVE
B

RFD

E
CONTENTS
PREPARATION ........................................................... 2 ASSEMBLY (R200 2–PINION) ............................ 18 F
Special Service Tools ............................................... 2 DISASSEMBLY OF DIFFERENTIAL CASE
Commercial Service Tools ........................................ 4 ASSEMBLY(R200V) ............................................ 20
NOISE, VIBRATION AND HARSHNESS (NVH) INSPECTION ...................................................... 21 G
TROUBLESHOOTING ................................................ 5 ADJUSTMENT OF DIFFERENTIAL CASE (R200
NVH Troubleshooting Chart ..................................... 5 2–PINION) ........................................................... 21
FRONT OIL SEAL ...................................................... 6 ADJUSTMENT OF DIFFERENTIAL CASE
H
Removal and Installation .......................................... 6 (R200V) ............................................................... 22
REMOVAL ............................................................. 6 SIDE BEARING PRELOAD ................................. 23
INSTALLATION ..................................................... 7 PINION GEAR HEIGHT ...................................... 24
SIDE OIL SEAL .......................................................... 8 TOOTH CONTACT .............................................. 27 I
Removal and Installation .......................................... 8 ASSEMBLY OF DIFFERENTIAL CASE ASSEM-
REMOVAL ............................................................. 8 BLY (R200 2–PINION) ......................................... 28
INSTALLATION ..................................................... 8 ASSEMBLY OF DIFFERENTIAL CASE ASSEM- J
REAR FINAL DRIVE ASSEMBLY ............................ 10 BLY (R200V) ........................................................ 29
Removal and Installation ........................................ 10 INSTALLATION OF DRIVE PINION ASSEMBLY... 30
REMOVAL ........................................................... 10 INSTALLATION OF DIFFERENTIAL CASE
K
INSTALLATION ....................................................11 ASSEMBLY ......................................................... 31
Components ........................................................... 12 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 34
R200 2–PINION .................................................. 12 General Specifications ............................................ 34
R200V VISCOUS ................................................ 14 Drive Gear Runout .................................................. 34 L
Pre-Inspection ........................................................ 15 Side Gear Adjustment ............................................ 34
TOTAL PRELOAD ............................................... 15 AVAILABLE SIDE GEAR THRUST WASHERS... 34
DRIVE GEAR TO DRIVE PINION BACKLASH... 15 Drive Pinion Height Adjustment .............................. 35 M
DRIVE GEAR RUNOUT ...................................... 15 AVAILABLE PINION HEIGHT ADJUSTING
TOOTH CONTACT .............................................. 15 WASHERS .......................................................... 35
Disassembly and Assembly ................................... 16 Drive Pinion Preload Adjustment ............................ 35
REMOVAL OF DIFFERENTIAL CASE ASSEM- Side Bearing Preload Adjustment ........................... 35
BLY ...................................................................... 16 SIDE BEARING ADJUSTING WASHERS .......... 35
REMOVAL OF DRIVE PINION ASSEMBLY ....... 17 Total Preload Adjustment ........................................ 35
DISASSEMBLY OF DIFFERENTIAL CASE

RFD-1
 PREPARATION

PREPARATION PFP:00002

Special Service Tools ADS0005U

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool name
Description
Tool number (Kent-Moore No.)

Drift
ST30720000 (J25405)
Installing front oil seal
a: 77 mm (3.03 in) dia.
b: 55 mm (2.17 in) dia.

ZZA0811D

Drift
KV38100200 (J26233)
Installing side oil seal
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.

ZZA1143D

Protector
Installing side flange
KV38107900 (J39352)

S-NT129

Attachment
KV38100800 (J25604-01)
Fixing unit assembly
a: 541 mm (21.30 in)
b: 200 mm (7.87 in)

SDIA0267E

Differential side bearing puller set

ST3306S001 ( – )
1.ST3305S001 ( – )
Removing and installing side bearing
2.ST33061000 (J8107–2)
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
NT072

Drift
ST30613000 (J25742-3) Installing pinion front and rear bearing outer
a: 72 mm (2.83 in) dia. race
b: 48 mm (1.89 in) dia.

ZZA0810D

Drift
KV38100300 (J25523)
a: 54 mm (2.13 in) dia. Installing side bearing
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia.
ZZA1046D

RFD-2
 PREPARATION

Tool name
Description A
Tool number (Kent-Moore No.)

Drive pinion flange wrench B

KV40104000 ( – )
Removing and installing drive pinion nut
a : 85 mm (3.35 in) dia.
b : 65 mm (2.56 in) dia.
C
NT659

RFD

Sliding hammer
Removing side flange
ST36230000 (J25840-A)
E

ZZA0803D

Axle stand
Removing side flange
KV40104100 ( – ) G

ZZA0804D
H

Slideing hammer I
Removing differential case assembly
HT72400000 ( – )

S-NT125 J
Drive pinion rear inner race puller set
ST3090S000 ( – )
1. ST30031000 (J22912-01) Puller K
2. ST30901000 ( – ) Base
Equivalent tool (J26010-01)
Removing and installing drive pinion rear
a : 90 mm (3.54 in) dia.
bearing inner race
b : 80 mm (3.15 in) dia. L
c : 50 mm (1.97 in) dia.
d : 79 mm (3.11 in) dia.
S-NT640
e : 45 mm (1.77 in) dia.
f : 35 mm (1.38 in) dia. M

Drift Installing pinion rear bearing outer race

ST30611000 (J25742–1) (Use with ST30613000)

S-NT090

Preload gauge
ST3127S000 (see J25765-A)
1. GG91030000
Torque wrench (J25765) Measuring pinion bearing preload and total
2. HT62940000 ( – ) preload
Socket adapter (1/2″)
3. HT62900000 ( – )
Socket adapter (3/8″) NT124

RFD-3
 PREPARATION

Tool name
Description
Tool number (Kent-Moore No.)

Oil seal puller

Removing fornt oil seal
ST33290001 (J34286)

ZZA0601D

Differential shim selection (J34309) Adjusting bearing preload gear height

NT134

Commercial Service Tools ADS0005V

Power tool

PBIC0190E

RFD-4
 Symptom
×: Applicable
Reference page

DIFFERENTIAL
Possible cause and SUSPECTED PARTS

Noise
NVH Troubleshooting Chart

×
Rough gear tooth Refer to RFD-21, "Contact Surfaces"

Improper gear contact Refer to RFD-27, "TOOTH CONTACT"

RFD-5
×
Tooth surfaces worn Refer to RFD-21, "Contact Surfaces"

Incorrect backlash Refer to RFD-15, "Pre-Inspection"

×
×
Companion flange excessive runout —

×
Improper gear oil Refer toMA-21, "CHASSIS AND BODY MAINTENANCE"

PROPELLER SHAFT NVH in PR section.

×
×
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU sections.

TIRES NVH in WT section.

×
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

×
ROAD WHEEL NVH in WT section.

×
DRIVE SHAFT NVH in RAX section.
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

× 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.

STEERING NVH in PS section.

PFP:00003

ADS0005W

L
F

K
E
B
A

H
C

M
RFD
 FRONT OIL SEAL

FRONT OIL SEAL PFP:38189

Removal and Installation ADS00081

REMOVAL
1. Remove the propeller shaft. Refer to PR-5, "REAR PROPELLER SHAFT" .
CAUTION:
Do not impact or damage propeller shaft tube.
2. Put a mark on the end of the drive pinion corresponding to the B
position mark on the companion flange.
CAUTION:
● For matching mark, use paint. Never damage drive pin-
ion.
● The mark on the final drive companion flange indicates
the maximum vertical runout position.

SDIA0270E

3. Using the drive pinion flange wrench, Remove drive pinion nut.
Tool number : KV40104000 ( – )

SDIA1142E

4. Using the puller, remove the companion flange.

SDIA1054E

5. Using the oil seal puller, remove front oil seal.

Tool number : ST33290001 (J34286)

SDIA1003E

RFD-6
 FRONT OIL SEAL

INSTALLATION
1. Apply multi-purpose grease to sealing lips of oil seal. Press front A
oil seal into carrier with tool.
Tool number : ST30720000 (J25405)
B
CAUTION:
● When installing the oil seal, be careful not to get it
inclined.
● Discard the old oil seal. Always replace with new one.
C

SDIA1004E
RFD

2. Align the matching mark of drive pinion with the matching mark
B of companion flange, then install the companion flange. E

SDIA0270E

H
3. Apply oil or grease on the screw part of drive pinion and the seating surface of drive pinion nut.
4. Install drive pinion nut with tool.
Tool number : KV4010400 ( – ) I

: 147 - 323N·m (15.0 - 32.0 kg-m, 109 - 238 ft-lb)

J
CAUTION:
The drive pinion nut is not reusable. Never reuse drive pinion nut.
5. Install propeller shaft. Refer to PR-5, "REAR PROPELLER SHAFT" .
K

RFD-7
 SIDE OIL SEAL

SIDE OIL SEAL PFP:33142

Removal and Installation ADS0006Q

REMOVAL
1. Remove side flange with the following procedure for press-fitting.
a. Remove rear ABS wheel sensor. Refer to BRC-85, "WHEEL SENSORS" .
b. Remove drive shaft. Refer to RAX-10, "REAR DRIVE SHAFT" and RAX-6, "WHEEL HUB" .
c. Install axle stand to side flange.
Tool number A : KV40104100 ( – )
d. Using a sliding hammer, pull out the side flange.
Tool number B : ST36230000 (J25840–A)

SDIA1005E

Circular clip installation position

Model
Right side Left side
R200 Final drive side
R200V Final drive side Side flange side

2. Remove oil seal using a flat-bladed screwdriver.

SDIA1036E

INSTALLATION
NOTE:
Be sure to install the RH companion flange of the R200V, then install the LH companion flange. If LH compan-
ion flange is installed first, the RH companion flange comes out sometimes from the shock of installing the RH
companion flange.
1. Apply multi-purpose grease to sealing lips of side oil seal.

2. Using the drift, press-fit oil seal so that its surface comes face to
face with the end surface of the case.
Tool number : KV38100200 (J26233)
CAUTION:
● When installing the oil seal be careful not to get it
inclined.
● Discard the old oil seal. Always replace with new one.

SDIA1037E

RFD-8
 SIDE OIL SEAL

3. Install the side flange with the following procedure.

a. Attach the protector to side oil seal. A

Tool number : KV38107900 (J39352)

b. After the side flange is inserted and the serrated part of side B
gear has engaged the serrated part of flange, remove the pro-
tector.
C

SDIA0822E

RFD
c. Put suitable drift on the center of side flange, then drive it until
sound changes.
NOTE: E
When installation is completed, driving sound of the side flange
turns into a sound which seems to affect the whole final drive.
4. Confirm that the dimension of the side flange installation (Mea-
F
surement A) in the illustration comes into the following, then
install the drive shaft.
Measurement A G
: Approx. 326 - 328 mm (12.83 - 12.91 in) SDIA0276E

5. Align the installing position of the ABS wheel sensor. Refer to BRC-85, "WHEEL SENSORS" . H

RFD-9
 REAR FINAL DRIVE ASSEMBLY

REAR FINAL DRIVE ASSEMBLY PFP:38300

Removal and Installation ADS0006R

SDIA1980E

1. Breather hose 2. Final drive 3. Rear propeller shaft

4. Washer 5. Lower stopper 6. Drive shaft
7. Rear final drive assembly 8. Upper stopper

REMOVAL
1. Remove rear propeller shaft from the final drive. Refer to PR-7, "REMOVAL" .
CAUTION:
Do not impact or damage propeller shaft tube.
2. Remove rear stabilizer bar with power tool. Refer to RSU-16, "STABILIZER BAR" .
3. Remove drive shaft from final drive. Then suspend it by wire etc.
Refer to RAX-10, "REAR DRIVE SHAFT" .
4. Remove breather hose from the final drive.
5. Remove ABS wheel sensor. Refer to BRC-85, "WHEEL SEN-
SORS" .
6. Place a transmission jack on the final drive.
CAUTION:
Do not place a transmission jack on the rear cover (alumi-
num case).
7. Remove the mounting bolts and nuts connecting to the suspen- SDIA1094E
sion member, and remove the rear final drive.

RFD-10
 REAR FINAL DRIVE ASSEMBLY

INSTALLATION
Install in the reverse order of removal. A
CAUTION:
After installation, check the final drive oil level. Refer to MA-24, "Checking Differential Gear Oil" .
B

RFD

RFD-11
 REAR FINAL DRIVE ASSEMBLY

Components ADS0006S

R200 2–PINION

SDIA1023E

RFD-12
 REAR FINAL DRIVE ASSEMBLY

1. Drive pinion nut 2. Companion flange 3. Front oil seal

4. Pinion front bearing 5. Pinion bearing adjusting spacer 6. Pinion rear bearing
A
(Collapsible spacer)
7. Pinion height adjusting washer 8. Drive pinion 9. Side oil seal
10. Drive gear 11. Pinion mate shaft 12. Look pin B
13. Pinion mate gear 14. Pinion mate thrust washer 15. Side gear
16. Side gear thrust washer 17. Differential case 18. Side bearing
19. Side bearing adjusting washer 20. Bearing cap 21. Rear cover C
22. Filler plug 23. Drain plug 24. Gear carrier
25. Circular clip 26. Gasket
RFD

RFD-13
 REAR FINAL DRIVE ASSEMBLY

R200V VISCOUS

SDIA1022E

RFD-14
 REAR FINAL DRIVE ASSEMBLY

1. Drive pinion nut 2. Companion flange 3. Front oil seal

4. Pinion front bearing 5. Pinion bearing adjusting spacer 6. Pinion rear bearing
A
(Collapsible spacer)
7. Pinion height adjusting washer 8. Drive pinion 9. Side oil seal
10. Drive gear 11. Pinion mate shaft 12. Pinion mate gear B
13. Pinion mate thrust washer 14. Side gear thrust washer 15. Side gear
16. Viscous coupling 17. Side gear thrust washer 18. Differential case B
19. Differential case A 20. Side bearing 21. Side bearing adjusting washer C
22. Bearing cap 23. Rear cover 24. Filler plug
25. Drain plug 26. Gear carrier 27. Circular clip
28. Gasket RFD

Pre-Inspection ADS0006T
E
Before disassembling final drive, perform the following inspection.
TOTAL PRELOAD
1. Turn drive pinion in both directions several times to set bearing F
rollers.
2. Check total preload with Tool.
G
Tool number
: ST3127S000 (see J25765-A)
Total preload H
: 2.84 - 3.75 N·m (0.29 - 0.38 kg-m, 26 - 33 in-lb)

SPD884
I

DRIVE GEAR TO DRIVE PINION BACKLASH

Check drive gear to drive pinion backlash with a dial gauge at sev- J
eral points.
Drive gear backlash
: 0.10 - 0.15 mm (0.0039 - 0.0059 in) K

SPD513 M
DRIVE GEAR RUNOUT
Check runout of drive gear with a dial gauge.
Runout limit : 0.05 mm (0.0020 in) less

SPD886

TOOTH CONTACT
Check tooth contact. Refer to RFD-27, "TOOTH CONTACT" .

RFD-15
 REAR FINAL DRIVE ASSEMBLY

Disassembly and Assembly ADS0006U

REMOVAL OF DIFFERENTIAL CASE ASSEMBLY

1. Using two 45 mm (1.77 in) spacers, mount carrier on Tool.
Tool number : KV38100800 (J25604–01)

SPD888

2. For proper reinstallation, paint match marks on one side of the

bearing cap.
Bearing caps are line-board during manufacture. Replace them
in their proper positions.

SPD889

3. Remove bearing caps.

S-PD343

4. Lift differential case assembly out with Tool.

Tool number : HT72400000 ( – )

S-PD344

RFD-16
 REAR FINAL DRIVE ASSEMBLY

● Keep the side bearing outer races together with inner races.
Do not mix them up. A
Also, keep adjusting washers together with bearings.

SPD919

RFD
REMOVAL OF DRIVE PINION ASSEMBLY
1. Put match marks on companion flange and drive pinion with
paint. E
2. Loosen drive pinion nut with tool.
Tool number : KV40104000 ( – )
F

SDIA1144E

H
3. Using the puller remove companion flange.

K
SDIA1132E

4. Take out drive pinion (together with rear bearing inner race,
bearing adjusting spacer). L
5. Remove front oil seal. Refer to RFD-6, "FRONT OIL SEAL"
6. Remove pinion front bearing inner race.
M
7. Remove side oil seal. Refer to RFD-8, "SIDE OIL SEAL"

SPD892

RFD-17
 REAR FINAL DRIVE ASSEMBLY

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

SDIA0817E

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

S-PD179

DISASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY (R200 2–PINION)

1. Remove side bearing inner races.
To prevent damage to bearing, engage puller jaws in groove.
Tool number : A ST3305S001 ( – )
: B ST33061000 (J8107-2)

SPD920

RFD-18
 REAR FINAL DRIVE ASSEMBLY

● Be careful not to confuse left- and right-hand parts.

A

SPD022

RFD
2. Loosen drive gear bolts in a criss-cross fashion.
3. Tap drive gear off the differential case with a soft hammer.
● Tap evenly all around to keep drive gear from binding. E

G
SPD024

4. Drive out pinion mate shaft lock pin with punch from drive gear H
side.

SPD025
K

RFD-19
 REAR FINAL DRIVE ASSEMBLY

DISASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY(R200V)

1. Remove side bearing inner race.
To prevent damage to bearing, engage puller jaws in groove.
Tool number : A ST3305S001 ( – )
: B ST33061000 (J8107-2)

SDIA0818E

● Be careful not to confuse left- and right-hand parts.

SPD022

2. Loosen drive gear bolts in a criss-cross fashion.

3. Tap ring gear off the differential case with a soft hammer.
● Tap evenly all around to keep drive gear from binding.

SPD024

RFD-20
 REAR FINAL DRIVE ASSEMBLY

4. Put match marks with paint

5. Loosen screws on differential cases A and B. A
6. Separate differential cases A and B.

SPD862

RFD
INSPECTION
Contact Surfaces
1. Clean the disassembled parts in suitable solvent and blow dry with compressed air. E
2. If following surfaces are found to be burred or scratched, smooth with oil stone.
● Differential case

● Side gear F
● Pinion mate gear

● Pinion mate shaft

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

SPD715

ADJUSTMENT OF DIFFERENTIAL CASE (R200 2–PINION) K

Thrust Washer Selection
1. Install side gears, pinion mate gears, thrust washers into differ-
ential case. L

SPD552

RFD-21
 REAR FINAL DRIVE ASSEMBLY

2. Fit pinion mate shaft to differential case so that it meets lock pin
holes.

SPD553

3. Adjust clearance between rear face of side gear and thrust washer by selecting side gear thrust washer.
Refer to RFD-34, "AVAILABLE SIDE GEAR THRUST WASHERS" .
Use two feeler gauges to prevent leaning of side gear as shown,
figure.
Clearance between side gear thrust washer and differ-
ential case
: 0.20 mm (0.0079 in) less

SPD828

ADJUSTMENT OF DIFFERENTIAL CASE (R200V)

Side gear Thrust Washer Selection
Whenever side gears or pinion mate gears are replaced, select suit-
able thrust washers as follows:
1. Clean side gears and pinion mate gears using white gasoline.
2. Before assembling gears, apply hypoid gear oil to frictional sur-
faces.
3. Install the previously removed thrust washer on right side gear.
On left side gear, install a suitable thrust washer.
Temporarily tighten differential cases using two screws.
4. Position differential assembly so that right side gear is on the
upper side. Place feeler gauge of 0.03 mm (0.0012 in) thickness SDIA1146E
between right side gear and thrust washer as shown.
● Do not place feeler gauge at groove side of differential case.
5. Also place a 0.03 mm (0.0012 in) additional feeler gauge between right side gear and thrust washer so
that it is positioned diagonal to (180° apart from) the feeler gauge described previously.
6. Rotate right side gear with a suitable tool attached to splines. If hard to rotate, replace thrust washer on
left side gear with a thinner one.
7. Replace both 0.03 mm (0.0012 in) feeler gauges with 0.15 mm (0.0059 in) gauges. At this point, make
sure right side gear does not rotate. If it rotates, replace thrust washer on left side gear with a thicker one
to prevent rotation.
8. As explained in above example, select suitable thrust washers to ensure that:
a. Both side gears rotate. [0.03 mm (0.0012 in) feeler gauges are used in this case.]
b. Side gear is held stationary. [0.15 mm (0.0059 in) feeler gauges are used in this case.]

For quiet and reliable final drive operation, the following five adjustments must be made correctly.
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload
4. Drive gear to pinion backlash.

RFD-22
 REAR FINAL DRIVE ASSEMBLY

5. Drive and pinion gear tooth contact pattern

A
SIDE BEARING PRELOAD

A selection of carrier side bearing adjusting washers is required for successful completion of this procedure.
B
1. Make sure all parts are clean. Also, make sure the bearings are
well lubricated with light oil or DEXRONTM type automatic trans-
mission fluid.
C
2. Place the differential case assembly, with side bearing outer
races installed, gear carrier.

RFD

E
SPD527

3. Insert left and right side bearing adjusting washer in place

between side bearings and gear carrier. F

SPD924
I
4. Install the bearing caps in their correct locations and torque the
bearing cap retaining bolts.
J
: 88 - 98 N·m (9.0 - 9.9 kg-m, 65 - 72 ft.-lb)
5. Turn the carrier several times to seat the bearings.
K

L
SPD526

6. Measure the turning torque of the carrier at the drive gear retain- M
ing bolts with a spring gauge, J-8129.
Specification
: 34.2 - 39.2 N (3.5 - 4 kg, 7.7 - 8.8 lb)
of pulling force at the drive gear bolt

SPD194A

RFD-23
 REAR FINAL DRIVE ASSEMBLY

7. If the turning torque is not within the specifications, correct the

torque as follows:
● If the turning torque is less than the specified range, install
washers of greater thickness.
● If the turning torque is greater than the specification, install
thinner washers.
● See the SDS section for washer dimensions and part num-
bers.
8. Record the total amount of washer thickness required for the
correct carrier side bearing preload. SPD772

9. Remove the carrier from the final drive housing. Save the
selected washers for later use during the assembly of the final
drive unit.
Tool number : HT72400000 ( – )

S-PD344

PINION GEAR HEIGHT

1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion bearings into the differential shim selection
Tool, J34309.

SPD769

● Pinion front bearing; make sure the J34309-3 pinion front bear-
ing seat is secured tightly against the J34309-2 gauge anvil.
Then turn the pinion front bearing pilot, J34309-5, to secure the
bearing in its proper position.
● Rear pinion bearing; the pinion rear bearing pilot, J34309-8, is
used to center the pinion rear bearing only. The pinion rear bear-
ing locking seat, J34309-4, is used to lock the bearing to the
assembly.
● Installation of J34309-9 and J34309-16; place a suitable 2.5 mm
(0.098 in) thick plain washer between J34309-9 and J34309-16.
Both surfaces of J34309-9 and J34309-16 must be parallel with SPD197A

a clearance of 2.5 mm (0.098 in).

RFD-24
 REAR FINAL DRIVE ASSEMBLY

3. Install the pinion rear bearing inner race into the final drive hous-
ing. Then place the pinion preload shim selector Tool, J34309-1, A
gauge screw assembly.

SPD893

RFD
4. Assemble the front pinion bearing inner race and the J34309-2
gauge anvil. Assemble them together with the J34309-1 gauge
screw in the final drive housing. Make sure that the pinion height
E
gauge plate, J34309-16, will turn a full 360 degrees. Tighten the
two sections together by hand.

G
SPD199A

5. Turn the assembly several times to seat the bearings. H

SPD770
K
6. Measure the turning torque at the end of the J34309-2 gauge
anvil using torque wrench J-25765A.
L
Turning torque specification
: 1.0 - 1.3 N·m(0.11 - 0.13 kg-m, 9 - 11 in-lb)
M

SPD234A

7. Place the J34309-11 “R200A” pinion height adapter onto the

gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

SPD208A

RFD-25
 REAR FINAL DRIVE ASSEMBLY

Pinion Height Adjusting Washer Selection

1. Now, position the side bearing discs, J25269-4, and arbor firmly
into the side bearing bores. Install the bearing caps and tighten
the cap bolts to proper torque.

SPD211A

2. Select the correct standard pinion height adjusting washer thick-

ness. Select by using a standard gauge of 3 mm (0.12 in) and
your J34309-101 feeler gauge. Measure the distance between
the J34309-11 pinion height adapter including the standard
gauge and the arbor.

SPD204A

3. Write down your exact measurement (the value of feeler gauge).

SPD775

4. Correct the pinion height washer size by referring to the “pinion

head number”.

SPD542

There are two numbers painted on the drive pinion gear. The first one refers to the drive pinion and drive gear
as a matched set. This number should be the same as the number on the drive gear. The second number is
the “pinion head height number”. It refers to the ideal pinion height from standard for quietest operation. Use
the following chart to determine the correct pinion height washer.

RFD-26
 REAR FINAL DRIVE ASSEMBLY

Add or remove from the standard A

Pinion head height number
pinion height washer thickness measurement
-6 Add 0.06 mm (0.0024 in)
-5 Add 0.05 mm (0.0020 in)
-4 Add 0.04 mm (0.0016 in) B
-3 Add 0.03 mm (0.0012 in)
-2 Add 0.02 mm (0.0008 in)
-1 Add 0.01 mm (0.0004 in)
C
0 Use the selected washer thickness
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in) RFD
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)
E
5. Select the correct pinion height washer as follows. Refer to RFD-35, "AVAILABLE PINION HEIGHT
ADJUSTING WASHERS" .
6. Remove the J34309 pinion differential shim selection Tool from
the final drive housing. Then disassemble to retrieve the pinion F
bearings.

SPD205A
I
TOOTH CONTACT
Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive
pinion. J
Hypoid gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check
gear tooth contact pattern to obtain the best contact for low noise and long life.
K
1. Thoroughly clean drive gear and drive pinion teeth.
2. Lightly apply a mixture of powdered ferric oxide and oil or the
equivalent. Apply it to 3 or 4 teeth of drive gear drive side. L

SPD357

3. Hold companion flange steady by hand and rotate the drive gear
in both directions.

SDIA0813E

RFD-27
 REAR FINAL DRIVE ASSEMBLY

SDIA1910E

ASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY (R200 2–PINION)

1. Install pinion mate shaft lock pin with a punch.
Make sure lock pin is flush with case.

SPD030

2. Place differential case on drive gear.

3. Apply genuine medium strength locking sealant or equivalent.
Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS
AND SEALANTS" to drive gear bolts, and install them.
● Tighten bolts in a criss-cross fashion.
● After tightening the bolt to the specified torque, turn the bolt 31
to 36 more degrees.

SPD554

4. Press-fit side bearing inner races on differential case with Tool.

Tool number : A KV38100300 (J25523)
: B ST33061000 (J8107-2)

SPD353

RFD-28
 REAR FINAL DRIVE ASSEMBLY

ASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY (R200V)

1. Install differential cases A and B. A
: 3.8 - 5.8 N·m(0.39 - 0.59 kg-m, 34 - 51 in-lb)

RFD
SPD862

2. Place differential case on drive gear.

E
3. Apply genuine medium strength locking sealant or equivalent.
Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS
AND SEALANTS" to drive gear bolts, and install them.
F
● Tighten bolts in a criss-cross fashion.
● After tightening the bolt to the specified torque, turn the bolt 31
to 36 more degrees.
G

SPD554
H

4. Press-fit side bearing inner races on differential case with Tool.

Tool number : A KV38100300 (J25523) I
: B ST33061000 (J8107-2)

SPD353

RFD-29
 REAR FINAL DRIVE ASSEMBLY

INSTALLATION OF DRIVE PINION ASSEMBLY

1. Press-fit pinion front and rear bearing outer races with Tools.
Tool number : A Suitable tool
: B ST30611000 (J25742-1)
: C ST30613000 (J25742-3)

SPD992

2. Select pinion height adjusting washer. Refer to RFD-26, "Pinion Height Adjusting Washer Selection" .

3. Install selected pinion height adjusting washer in drive pinion.

Using press and Tool, press-fit pinion rear bearing inner race
into it.
Tool number : ST30901000 ( – )

SPD377

4. Set drive pinion assembly (as shown in figure) in differential car-

rier and install drive pinion, with press and suitable tool.
Stop when drive pinion touches bearing.
Apply multi-purpose grease to pinion rear bearing inner race
and pinion front bearing inner race.

SDIA0826E

RFD-30
 REAR FINAL DRIVE ASSEMBLY

SPD896

5. Install front oil seal with Tool. Refer toRFD-6, "Removal and Installation" . RFD

6. Install companion flange, and tighten pinion nut to minimum.

Ascertain that threaded portion of drive pinion and drive pinion E
nut are free from oil or grease.
Tool number : KV40104000 ( – )
CAUTION: F
The drive pinion nut is not reusable. Never reuse drive pinion
nut.
G

SDIA1145E

H
7. Tighten the drive pinion nut by very small degrees until the spec-
ified preload in achieved, when checking the preload, turn drive
pinion in both directions several times. I
Tool number
: ST3127S000 (See J25765-A)
J
Pinion bearing preload
: 2.65 - 3.23 N·m (0.27 - 0.32 kg-m, 24 - 28 in-lb)
K
SPD884

● If pinion bearing preload is too small, tighten the drive pinion nut more. L
● If pinion bearing preload is too great, replace pinion bearing adjusting spacer.

INSTALLATION OF DIFFERENTIAL CASE ASSEMBLY M

1. Select side bearing adjusting washer. Refer to RFD-23, "SIDE
BEARING PRELOAD" .
2. Install differential case assembly with side bearing outer races
into gear carrier.

SPD919

RFD-31
 REAR FINAL DRIVE ASSEMBLY

3. Insert left and right side bearing adjusting washers in place

between side bearings and carrier.

SPD924

4. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.
: 88 - 98 N·m (9.0 - 9.9 kg-m, 65 - 72 fl-lb)

SPD889

5. Install side oil seal. Refer to RFD-8, "Removal and Installation" .

6. Measure drive gear-to-drive pinion backlash with a dial indicator

at several point.
Drive gear backlash
: 0.10 - 0.15 mm (0.0039 - 0.0059 in) less

SPD513

● It backlash is too small, adjustment of washer thickness is required. Decrease thickness of left shim and
increase thickness of right by the same amount.
If backlash is too great, reverse the above procedure.
● Never change the total amount of washers as it will change the bearing preload.

7. Check total preload with Tool.

Tool number : ST3127S000 (See J25765-A)

SPD884

When checking preload, turn drive pinion in both directions several times to seat bearing rollers correctly.
Total preload : 2.84 - 3.75 N·m (0.29 - 0.38 kg-m, 26 - 33 in-lb)

RFD-32
 REAR FINAL DRIVE ASSEMBLY

● If preload is too great, remove the same amount of washer to each side.
● If preload is too small, add the same amount of washer to each side. A
Never add or remove a different number of washers for each side. Difference in number of washers will
change drive gear to drive pinion backlash.
8. Recheck drive gear to drive pinion backlash. Increase or decrease in thickness of shims will cause B
change to drive gear to pinion backlash.
● Check whether the backlash varies excessively in different places. Foreign matter may be caught
between the drive gear and the differential case causing the trouble. C
● The backlash can vary greatly even when the drive gear runout is within a specified range. In that case,
replace the hypoid gear set or differential case.
9. Check runout of drive gear with a dial indicator. RFD
Runout limit : 0.05 mm (0.0020 in) less
10. Check tooth contact. E
Refer to RFD-27, "TOOTH CONTACT" .

SPD524 G

11. Install rear cover. Apply sealant to rear cover side and install
gear carrier. H

SDIA0970E

RFD-33
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications ADS0008B

VQ35DE engine
Applied model
M/T A/T
Final drive model R200 (2 − pinion) R200V (LSD)
Gear ratio 3.538 3.357
Number of teeth (Drive gear / drive pinion) 46 / 13 47 / 14
Oil capacity (Approx.) 1.4 liter (3 US pt, 2 - 1/2 Imp pt)

Drive Gear Runout ADS0008C

Unit: mm (in)
Type R200, R200V
Drive gear runout limit 0.05 (0.0020) less

Side Gear Adjustment ADS0008H

Unit: mm (in)
Type R200 R200V
Clearance limit between side gear and differential case mm (in) 0.20 (0.0079) less 0.15 (0.0059) less

AVAILABLE SIDE GEAR THRUST WASHERS

Unit: mm (in)
Type R200 R200V
Thickness Part number Thickness Part number
0.75 (0.0295) 38424 0C000 0.80 (0.0315) 38424 40F60
0.78 (0.0307) 38424 0C001 0.83 (0.0327) 38424 40F61
0.81 (0.0319) 38424 0C002 0.86 (0.0339) 38424 40F62
0.84 (0.0331) 38424 0C003 0.89 (0.0350) 38424 40F63
0.87 (0.0343) 38424 0C004 0.92 (0.0362) 38424 40F64
0.90 (0.0350) 38424 0C005 0.95 (0.0374) 38424 40F65
0.93 (0.0366) 38424 0C006 0.98 (0.0386) 38424 40F66
1.01 (0.0398) 38424 40F67
1.04 (0.0409) 38424 40F68
1.07 (0.0421) 38424 40F69
1.10 (0.0433) 38424 40F70
Thrust washer 1.13 (0.0445) 38424 40F71
1.16 (0.0457) 38424 40F72
1.19 (0.0469) 38424 40F73
1.22 (0.0480) 38424 40F74
1.25 (0.0492) 38424 40F75
1.28 (0.0504) 38424 40F76
1.31 (0.0516) 38424 40F77
1.34 (0.0528) 38424 40F78
1.37 (0.0539) 38424 40F79
1.40 (0.0551) 38424 40F80
1.43 (0.0563) 38424 40F81
1.46 (0.0575) 38424 40F82
1.49 (0.0587) 38424 40F83

RFD-34
 SERVICE DATA AND SPECIFICATIONS (SDS)

Drive Pinion Height Adjustment ADS0008J

AVAILABLE PINION HEIGHT ADJUSTING WASHERS A

Unit: mm (in)
Type R200, R200V
Thickness Part number Thickness Part number B
3.05 (0.1201) 38154 0C000 3.35 (0.1319) 38154 0C010
3.08 (0.1213) 38154 0C001 3.38 (0.1331) 38154 0C011
C
3.11 (0.1224) 38154 0C002 3.41 (0.1343) 38154 0C012
3.14 (0.1236) 38154 0C003 3.44 (0.1354) 38154 0C013
Adjusting washer 3.17 (0.1248) 38154 0C004 3.47 (0.1366) 38154 0C014 RFD
3.20 (0.1260) 38154 0C005 3.50(0.1378) 38154 0C015
3.23 (0.1272) 38154 0C006
E
3.26 (0.1283) 38154 0C007
3.29 (0.1295) 38154 0C008
3.32 (0.1307) 38154 0C009 F
Drive Pinion Preload Adjustment ADS0008K

Type R200, R200V G

Drive pinion preload 2.65 − 3.23 N·m (0.27 − 0.32 kg−m, 24 − 28 in lb)

Side Bearing Preload Adjustment ADS0008L

H
Type R200, R200V
Side bearing preload <Reference value> 0.20 − 0.52 N·m (0.02 − 0.05 kg−m, 2 − 4 in lb)
I
Torque by spring gauge 34.2 − 39.2 N (3.5 − 4 kg, 7.7 − 8.8 lb)

SIDE BEARING ADJUSTING WASHERS

Unit: mm (in) J
Type R200, R200V
Thickness Part number Thickness Part number
K
2.00 (0.0787) 38453 N3100 2.35 (0.0925) 38453 N3107
2.05 (0.0807) 38453 N3101 2.40 (0.0945) 38453 N3108
2.10 (0.0827) 38453 N3102 2.45 (0.0965) 38453 N3109 L
Adjusting washer
2.15 (0.0846) 38453 N3103 2.50 (0.0984) 38453 N3110
2.20 (0.0866) 38453 N3104 2.55 (0.1004) 38453 N3111
M
2.25 (0.0886) 38453 N3105 2.60 (0.1024) 38453 N3112
2.30 (0.0906) 38453 N3106 2.65 (0.1043) 38453 N3113

Total Preload Adjustment ADS0008M

Type R200, R200V

Total preload with oil seal 2.84 − 3.75 N·m (0.29 − 0.38 kg−m, 26 − 33 in lb)
Drive gear to drive pinion backlash 0.10 − 0.15 mm (0.0039 − 0.0059 in)

RFD-35
SERVICE DATA AND SPECIFICATIONS (SDS)

RFD-36