4WD SYSTEM SUBARU. 1992 SERVICE MANUAL e ‘M MECHANISM AND FUNCTION .. 2 1, Propeller Shatt .. 2 2, Rear Differential 3 3. Limited Slip Differential (LSD) .. 4 $ SPECIFICATIONS AND SERVICE DATA. 6 © COMPONENT PARTS ... 9 1, Rear Differential Mounting System 9 2, Propeller Shaft and Drive Shaft 10 3. Rear Differential Assembly 1 W SERVICE PROCEDURE 12 1, Propeller Shaft 12 2. Rear Differential 4 T TROUBLESHOOTING 30 1. Rear Differential 2, Propeller Shaft3-4 M109} 4WD SYSTEM M MECHANISM AND FUNCTION 1. Propeller Shaft ‘The propeller shaft model utilizes a 2-piece design that is provided with three joints. ‘Transmission side Center mounting, ea differential side Fig. 13-4 [M301] 3. Limited Slip Differential (LSD) viscous coupling (VC) type LSD has been adopted so ‘as to ensure safe and smooth transfer of increased power under various driving conditions. This VC type USD features ease of tuning while mainteining excel- lent stability when driving over slippery roads or when using engine brake, thus enabling engine power to be utilized efficiently. Smooth restriction of the differential operation of the left and right wheels results in improved running stability on bad roads, snowy roads, and also on muddy roads 1. STRUCTURE The VC type LSD adopts @ “shaft to shaft system” in which the RH and LH rear drive shafts are coupled by a VC. This results in a compact structure with high perfor- mance. The inside of the VC housing is formed by alternately combining the outer plates (the auter periphery of each plate engages with the internal spline of the housing) and inner plates (the inner periphery of each plate engages with the outer spline of the hub). On the outer periphery of the outer plate, the spacer ring is fitted and sat in position. On the inner plate, no positioning ring is used: The plate can be moved a cer- tain amount on the hub spline in the axial direction. Sealed inside the housing is a mixture of high viscosity on oil and air. The housing is sealed by X.rings so that silicon oil will not leak into the rear final drive even when the pressure increases due to a greater difference in the rotation speed between LH and RH wheels. The spindle (LH) which is integral with the rear drive shaft (LH) is coupled by the VC case spline, and is fitted to the side gear (LH) which is integral with the VC case. The spindle (RH) which is integral with the rear drive shaft (RH) is spline fitted to the side gear (RH). The end of the spindle is fitted by splines to the VC hub. No disassembling of the VC is allowed. 4WD SYSTEM ‘Viscous coupling cota] Fig. 3 2, OPERATION 1) When right and left wheels turn at equal speed During normal straight-road driving where the right and left wheels run at an equal speed, the differential case and side gears rotate together, just as in conventional differentials. As a result, driving torque is transmitted equally to the right and left side gears as shown in Fig- ure 4,4WD SYSTEM 2. Rear Differential Ahypoid drive gear with a nominal diameter of 160 mm (6.30 in) is used and the drive pinion shaft is supported ‘on three bearings, the bearing preload being adjusted [M200] _3-4 by a selective spacer and washer. The drive pinion height is adjusted by selecting washers located at the drive pinion neck using Dummy Shaft and Gauge. Reat deve shaft Is connected to spindle which is belted to dlterentat side gear, 3.961 Fig. 24WD SYSTEM LCyt 3130 Fig. 4 2) When right and loft wheels turn at different speeds. When a speed difference occurs between the right and left wheels, the VC housing and VC hub turn relatively at the same speed difference as that of the rear drive shaft, Because of the shearing force caused in the sili- con oil, a differential torque is generated, which con- trols differential operation (idle rotation). For example, if ‘the left wheel tums idle due to a difference in the road resistance, a speed difference occurs between the right and left wheel. Since the VC Is installed between the right and left wheels, a differential torque is generated in the VC corresponding to this speed difference, and this differential torque is transferred from the left wheel to the right wheel. Accordingly, @ greater driving force tm303]_3-4 is transferred to the right wheel which is rotating at @ lower speed as shown in Figure 5. Gy tat Fig. 6 3, SERVICE PROCEDURES FOR LSD ‘The component parts of LSD ASSY are not a piece parts. Therefore, it is recommended to not disassemble LSD assy. jlable as3-4 [SOA1} S SPECIFICATIONS AND SERVICE DATA 4WD SYSTEM. A: SPECIFICATIONS 1. REAR FINAL REDUCTION GEAR RATIO i800ce 200068, TURBO" ‘2200ce AT MT AT wT wT AT MT ‘Type of gear Hypoid Gear ratio (umber of | aaa aovo} | 4.114 (979) | a.aaa aays) | 4.111 (37/9) | 2646 (30/11) | 4.111 (37/9) | 3.900 (29/10) ‘gear tosth) ll eapacity 08 €(0.8 US at O7 Imp at) ‘=: With Ve type LSO 2. PROPELLER SHAFT NT ar Fulltime 4WO ‘Selective 4WD Front propeller shaft {lre.tc.jint length: 499 (10.25) 548 (21.57) 613 (24.13) Line fn) Outside dia, of | Dy 635 (2600) mm tin}| Oz 57.0 (2244) B o Fig. 64WD SYSTEM (SOAa]_3-4 3, DRIVE SHAFT SHAFT Type of dive shaft ASSY | Wo, of identification pad. | stance betwoon inner Diomatr (0) em fr) ‘GAC RH 304 (11.87) 26 088) et 204 (11.57) Peter 21.2 (0.836) 2 (Two) 2771084) 22.22 (7/8) BOS 267 (10.51) 22.22 (7/8) es2Rc-RH 282AC-LH NN) °87AC-RH ea Identification paddiogs (I rh Fig. 7 4. APPLICATION TABLE Power unit 200¢e 720006 20006 Turbo 220066 ‘ACH STAG AH a2AC-LH B7AGLH Drive shaft3.4 [SOBO) 4WD SYSTEM on lis back surface it cepacity Par No. B: SERVICE DATA 3Ho405200 | Si mm OTT) 322505200 [212 mm(0.1228 iy 322516200 [316 mm (01240 ny Rear differential ‘363525200 | 3.18 mm (0.1262 in) 329595000 — [321 mm gee in) ae Beaman 359545900 [24 mm{0"1276 in : low bearing | (20-28 3H2ss5200 [377 mma287 ny See $484.0 Seesae —_[oatem Gao, 334— 1687 383676200 [3 mm0.311 ny fone bottele| ectewing | (aasr ita, | | Roiontei ad | — Sitesi —[ Sapam aro 1,87 — 3.75 Ib). 383695200 3.39 mom {0.1335 in) Pano, gese0s200 [3 in 385705200 | 20mm ICO AL 389916000_——[ 248 mm 01380 i 3e5716200 [287 mm (0.1012) 3H90z5200 [48 mm/01370 i 363726200 [285 mm (0.1000 i 329095200 —[ 361 mmc 365795200 | 263mm (0.0866 i 329045200 | 364 mm/(0304 in} 36975200 | 281 mm (0.0080) 389655200 [557 mm (01406 in) 303765200 [2.49 mm (0.0860) ae26es200 ——[ 360-mm (0 47 in) Preioad adiusting [—sas7e5200—[ 27 mm 0.0972 i 3e2076200 [63 mm (0.1429 in washer lenath 365775200 | 24 mm (0.0905) 32005200 [3.66 mm (1441p sea7as200 [249mm 00057 i | | Sia goarto mst ‘01 =O mn sea70s200 [243 washer deacanco {0.004 — 0.008 In) senos200 [2 301mm (0.0861) Na 237 mn (0.0955 38> oem 363825200 2.36 mm (0.0928 in) Sid thrust een (0.0298 — 0.0316 in) 3095200 12°39 mm (0.0917) ic ore te qoasszer| 080066 mm 383845200 2.31 mm (0.0808 in) washer thickness {0.0318 — 0.0338 in) Pt No. 385 — 080 mm [“seaes5201 | 662mm BIS 382448208 | (0.0336 — 0.0354 in) proloed esting [288008202 [ss emm@zzo ln] | Side parry aan | aia mm 369995208 [$8.8 mm (2.228) lard wth (oer int 56os204 | 66.8 mm 2.296) Pantie 383605205 '67.0-mm (2.244 in} 7 7383475207 | 630 mm (0.0078 Jn) seaegsz08 | s7amm/azsz in | |, Side beating |-—~aezareze2 [9.28 mmm (0.0008 rat gao476208 [030 mmiO118 320476200 [040 mmf0.167 ny 380475205 [0560 mm (0.0197 Drive guar te Give 00020 mm ‘plrion backash (0.0038 — 0.0078) Drive gear runout Limit ‘0.05 mm (0.0020 in) 08 F108 US a 07 imp at)4WD SYSTEM {C100} 3-4 C COMPONENT PARTS 1. Rear Differential Mounting System 1 Differential front member 2 Stopper 3 Frontbushing 44 Differehttal mount bracket Differential mount front cover 6 Differential mount lower cover 7 pas eu but ©. Diforental ear member “Fahtening torques. New (ke-m, fe18) Tie 88 = 108 (911,68 80) 40 Proteetor (RH) 11 Prometor (LHD 5: 56 - 72 (6.7 -73, 41-59) Fig. 83-4 {C200} 4WD SYSTEM 2. Propeller Shaft and Drive Shaft ‘Tightening torque Nem (kg-m, ft-lb) Th 294 (25 1 Front proper shatt 2 Center besring 3 Companion tange 4 Rear propater shaft 5 Roar alferenal 8 7 8 9 11 Chop 18 Boot (01) 12 Snap ring 18 Boot band (B.) 48 Inner race (0) 20 BI ASSY 14 Bal 21 Spindle RH (VASD) 18. Boat band (00) 22 Onting (VLSD) 18. Boat (00) 23 Circ (VASO) 17 Boot band (Axle shan) 24. Spindle LM (V-LS0) Bere Fig. 9AWD SYSTEM [c300]_3-4 Tightening torque: Nem (kgm, ib) ‘Ti: 167 — 196 (17.0 — 20.0, 123 — 145) Ta ‘companion flange Non-L8D model Self locking nut 25 Sie goar thrust washer Side boating 27 Siée gear ‘#: Solactve parts Side beating retainer 2B Pion mato goar washer Diterentat carrier 28 Pion mate gear 1 Pinion crown gear sot Side of sal 0 Pion shaft lock pln 2 Diferential case 3 Pinion height adjusting washer 4 Rear bearing #5 Bearing preload adjusting specer #6 Beating preload adjusting washer Side bearing retaler O-ring 31. Difrential case ‘Side bearing retalner shim 32 Pinion mate shalt Bol (20x14 mn) Bolt (T1x18x41 mn) Rar cover + BSRVBsasaaeass 7. Front Boating Stud bolt 8 Spacer Plug 9 Plot bearing op 10 Front elt seat 25. Bolt (1020318 mm) Bote Fig. 103-4 [Wiad] 4WD SYSTEM W > SERVICE PROCEDURE 1. Propeller Shaft ‘A: ON-CAR SERVICE Check the following points with propeller shaft installed 1) Joints and connections Check for any looseness. of yoke flange connecting bolts and center bearing retaining bolts. 2) Splines and bearing locations Turn propeller shaft by hand to see if abnormal free play exists at splines. Also move yokes to see if abnor- mal free play exists at spiders and bearings. Fig. 17 3) Runout of propeller shaft ‘Turn rear wheels by hand to check for “runout” of pro- peller shaft, Run out: Limit 0.6 mm {0.024 in) Measure runout with a dial gauge at the center of front and rear propeller shaft tubes. 4) Center bearing free play While holding propeller shaft near center bearing with- your hand, move it up and down, and left and right to check for any abnormal bearing free play. REMOVAL Before removing propeller shaft, wrap metal parts with a cloth or rubbered material. 41) Remove rear exhaust pipe end muffler. 2) Reme ront cover of rear differential mount. Fig, 13 Fig. 14 4) Remove the two bolts which hold center bearing to car body.4WD SYSTEM Fig. 18 Fig. 16 ‘8. Bo sure to use an ompty ‘out when removing propeller 'b, Bo sure not to damage oll surface of sleeve yoke. Be aire to plug the opening in trensmission after removal of propeller shaft. nto catch oil flowing aft, Is and the frictional C: DISASSEMBLY Before removing center bearing, check its condition. If it does not operate smoothly or if there is any free play or leakage, remove as follows: [wico] 3-4 1) Put aligning marks on affected parts. Marching mak] a) L064 Fig. 17 2) Remove bolts which hold front propeller shaft to rear propeller shaft. 3) Place companion flange in a vise and remove stake nut. Be sure not to hold propeller shaft pipe portion in the vise. Fig. 18 4) Drive out companion flange with a puller or press. Before disassembling, put alignment mark on affected parts. 5) Lightly tap the head of front propeller shaft with copper hammer untit center bearing is removed. Be careful not to damage the thread portion.IwiDo] Copper hammer: Fig. 19 INSPECTION. Do not disassemble propeller shaft. Check the follow: Ing and replace if nacessary. 1) Tube surfaces for dents or cracks 2) Splines for deformation or abnormal wear 3) Joints for non-smocth operation or abnormal noise 4) Center bearing for free play, noise or non-smooth ‘operation 5) Oil seals for abnormal wear or damage 6) Center bearing for breakage ASSEMBLY 41) Install center bearing onto front propeller shaft. 2) Align marks end install companion flange. 3) Tighten stake nut until center bearing is set in posi- tion. Bo cure to install new stoke nut. Tightening torque: 245 — 294 Nem (25 — 30 kg- 181 — 217 ft-lb) ‘Stake the nut after tightening. 4) Align marks and connect front and rear propeller shafts. Tightening torque: 24 — 82 Nem (24 — 3,3 kg-m, 17 — 24 ft-lb) F: INSTALLATION 1) Insert sleeve yoke into transmission and attach cen- ter bearing to car body. Tightening torque: 47 — 87 Nem (4.8 — 8.8 kg-m, 35 — 42 ft-lb) AWD SYSTEM 2) Connect flange yoke and rear differe Tightening torque: 24 — 39 Nem (2.4 — 0 kg-m, 17 — 29 ft-lb) 3) Install front cover of rear differential mount. 4) Install rear exhaust pipe and muffler. 2. Rear Differential A: ON-CAR SERVICE 1. FRONT OIL SEAL 1) Drain gear oil, 2) Jack up rear wheels and support the vehicle body with rigid racks. 3) Remove propeller shaft from body. ‘Wrap motel parts with a cloth or rubbered material to prevent it from damage by interference with adjacent metal parts. 4) Measure turning resistance of compenion flange. Measure turning resistance after meking sure that the companion flange turns smoothly. Bo.146 Fig. 20 5} Remove self-locking nut while holding companion flange with FLANGE WRENCH. FLANGE WRENCH (398427700) B8147 Fig. 21 144WD SYSTEM 6) Extract companion flange with @ puller, 7) Remove oil seal. PULLER ASSY 13986277001 Fig. 24 849] 6) Drive out spring pin from DOM of rear drive shaft by Fig. 22 using 6 mm (0.24 in) diameter steel rod, 8) Fit a new oil seal. RIFT (998417700) 0150) Fig. 25 Fig. 28 7) Remove the DOJ from rear differential spindle while 9) Install companion flange. 10) Tighten self-locking nut within the specified torque range so that the turning resistance of companion flange becomes the same as that before replacing cil 167 — 196 Nem (17,0 — 20.0 kg-m, 123 — 145 ft-lb) 11) Reassembling procedure hereafter is the reverse of the disassembling. 2. SIDE OIL SEAL 1) Loosen both wheel nuts. 2) Jack up the vehicle and support it with rigid racks. 3) Remove wheels. 4) Remove bolt connecting lateral link to rear housing. Do not reuse self locking nut. 5) Remove bolt connecting trailing link to rear housing. Do not reuse self locking nut. Pushing rear housing outward. Suspend removed drive shaft using a wire, 8) Loosen differential spindle set bolt by using WRENCH and remove spindle with packing, (Non-LSD model) ‘Special tool: WRENCH (925560000) 9) Remove spindle using REMOVER and INSTALLER. {LSD model) pecial tool: REMOVER (499095500) INSTALLER (499247300) 153-4 [W2Az] 4WD SYSTEM 10) Remove oil seal. PULLER ASSY (398527700) 89-183 Fig. 26 11) Drive in a new oil seal with DRIFT. (Non-LSD model) Apply chassis grease between the oil seal lips. ‘Special took: DRIFT (398437700) 12) Assemble spindle into differential ASSY and tighten bolt with WRENCH. (Non-LSD model) ‘Special tool: WRENCH (926560000) on spindle, set spindle into differential and install by hitting it with a plastic ham- mer. (LSD model} Fe 83883 Fig. 27 16 2. Always use 8 new cirelip, b, Check that spindle thrust play is within specifica- tions. If not, check if spindle is completely driven into place. If itis, replace with a new one. ‘Specifications: 0.3 — 0.5 mm (0.012 — 0.020 in) ©. Check that oil seal lip is not folded over inward. 14) Reassembling procedure hereafter is the reverse of the disassembly.4WD SYSTEM {W280} 3-4 Using the different rear differential ASSY causes the B: IDENTIFICATION drive line and tires to “drag” ot emit abnormal noise when 4WD is selected. When replacing a rear differential ASSY, select the cor- tect one according to the following table, E> Location of abe cots Fig. 28 Gear ratio ‘denification mark Part number ‘Label stuck on rear diferent PaRT numeer 27011AA230 3.845 va 2701144230 VISCOUS LSD cear ratio 3.545, (© Fun savy WOUSTRES Ty @ PART ART en 2TOTIAAISI 800 wa 27011AAN61 cean nario 3.900 © Fa nowstas tra wa PART numacr 27011AATIT bil ia iaihaeiie cear nario 4.111 © fu sear oUsTRES 0 9 PART homoge 27011AA121 aa we zrotvaatay cean ratio 4.444 © run wear oust eT. w4 Fig. 29 33-0046 73-4 [w2co} AWD SYSTEM C: REMOVAL 4) Remove rear exhaust pipe and muffier. 2) Remove front cover of rear differential mount. 7) Remove lower differential bracket. Fig. 30 3) Remove propeller shaft. 8. Propare an oil can and cap since the transmission cil flows out from the extension at removing propeller shaft. b. When removing propeller shaft, pay attention not to damage the sliding surfaces of rear drive shaft (extension) spline, oil seal and sleeve yoke. 6. Insert the cap into the extension to prevent trans- mission oil from flowing out immediately after remov- ing the propeller shaft. 4) Remove spring pins from DOJ of rear drive shafts. 5) Remove heat sealed cover. 6) Remove clamps and bracket of parking brake cable. LLowsr differentia! racket regre| Fig. 32 8) Support rear differential with transmission jack. Fig. 33 9} Remove self-locking nuts connecting rear differen- tial to rear member,4WD SYSTEM [W200] _3-4 10) Remove bolts which secure rear differential front member to body. Loosen bolt @ first, then removal bolts @ . Support front member with the use of a helper to pre- vent it from dropping. Fig. 38 D: DISASSEMBLY To detect real cause of trouble, inspect the following items before disassembling, (Refer to “ASSEMBLY” for inspection procedures.) © Tooth contact of hypoid drive gear and pinion, and backlash ‘© Runout of drive gear at its back surface ‘© Turning resistance of drive pinion 1) Set ATTACHMENT on vise and install the differential assembly to Attachment. Fig. 35 11) While slowly lowering transmission jack, move rear differential forward and remove bolts from rear mem- ber. Fig. 36 12) Remove front member from body. (398217700) Fig. 39 2) Drain gear oil by removing plug. 3) Remove spindles with special tool. Special tool: Non-LSD model WRENCH (925560000) LSD model REMOVER (499095500) INSTALLER (499247300) eee Fig. 37 13) Remove rear drive shaft from rear remove rear differential from body. ntial, and 193-4 [W2d0] 4) Remove rear cover by loosening retaining bolts. Fig. 40 5) Make right and left side bearing retainer identify them st reassembly. Remove side beating retainer attaching bolts, set ATTACHMENT to differen- tial case, and extract right and left side bearing retainers with a puller. Each shim, whichis instelled to adjust the side bearing preload, should be kept together with its meting retainer. Side bearing catsiner Fig. 41 6) Pull out differential case. Be careful not to permit the teeth to contact the case, Differential ese 9.163 Fig. 42 AWD SYSTEM 7) When replacing side bearing, pull bearing cup from side bearing retainer, PULLER ASSY (398627700) Bearing cup Bs-164] 8) Extract bearing cone with PULLER SET. ‘#8. Set Puller so that its claws catch the edge of the bearing cone, b, Never mix up the right and left hand bearing cups ‘end cones. Do not attempt to disassemble the parts unless neces- sary. 9-165| Fig. 44 9) Remove drive gear by loosening drive gear bolts. Dittorential case (4WD SYSTEM Further disassembling of viscous LSD ASSY is not allowed. 10) Drive out pinion shatt lock pin from drive gear side. ‘The lock pin is staked at the pin hole end on the differ- ential cartier; do not drive it out forelbly before uns- taking it, 9.167) Fig. 46 11) Draw out pinion mate shaft and remove pinion mate gears, side gears and thrust washers. ‘The gears as well as thrust washers should be marked ‘or kept separated left and right, and front end rear. 12) Hold companion flange with FLANGE WRENCH and remove drive pinion nut. 13) Extract the companion flange with a puller. 14) Press th nd of drive pinion shaft and extract it together with rear bearing cone, preload adjusting ‘spacer and washer. Hold the drive pinion 60 as not to drop it, DRIFT (998467700) be-168] Fig. 47 15) Remove rear bearing cone from drive pinion by supporting cone with REPLACER. Place the replacer so that its center-recessed side feces Fig. the pinion gear. 2 weno] 3-4 REPLACER, Fear bearing cone (398517700) 3.169) Fig. 48 16) Remove front oil soal from differential carrier. 17) Remove pilot bearing together with front bearing cone. DRIFT (398467700) Front booring 33.170 Fig. 49 18) When replacing bearings, tap front bearing cup and rear bearing cup in this order out of case by using @ brass bar Sram tg? Bo7tIW2E9} 4WD SYSTEM E: INSPECTION Wesh all the disassembled parts clean, and examine them for wear, damage, or other defects. Repair or replace defective parts as necessary. 1) Drive gear and drive pinion (1) If abnormal tooth contact is evident, find out the cause and adjust to give correct tooth contact at assembly. Replace the gear if excessively worn or incapable of adjustment. (2) If crack, score, or seizure is evident, replace as @ set. Slight damage of tooth can be corrected by oil stone or the like, 2) Side gear and pinion mate gear (1) Replace if crack, score, or other defects ars evi- dent on tooth surface. (2) Replace if thrust washer contacting surface is worn or seized, Slight damage of the surface can be corrected by oil stone or the like, 3) Bearing Replace if seizure, peeling, wear, rust, dragging during rotation, abnormal noise or other defect is evident. 4) Thrust washers of side gear and pinion mate gear Replace if seizure, flaw, abnormal wear or other defect, is evident. 5) Oil seal Replace if deformed or damage sembling. 6) Differential carrier Replace if the bearing bores are worn or damaged. 7) Differential case Replace if its sliding surfaces are worn or cracked. 8) Companion Replace ifthe oil seal lip contacting surfaces have flaws. and at every disas- F: ASSEMBLY 1) Precautions for assembling (1) Assemble in the reverse order of disassembling. Check and adjust each part during assembly. (2) Keop the shims and washers in order, so that they are not misinstalled, (3) Thoroughly clean the surfaces on wi shims, washers and bearings are to be installed. (4) Apply gear oil when installing the bearings and thrust washers, (5) Be careful not to mix up the right and left hand cups of the bearings. (6) Replace the oil seal with new one at every disas- sembly. Apply chassis grease between the lips (*) When installing the oil seal. the 89-172] Fig. 51 2) Adjusting preload for front and rear bearings. Adjust the bearing preload with spacer and washer between front and rear bearings. Pinion height adjust- ing washer has nothing to do with this adjustment. The adjustment must be carried out without oil seal (1) Press front and rear bearing cups into differential carrier. HANDLE & ORIFT KIT: 1397471600) Fig. 52 {2) Insert DUMMY SHAFT with pit ing washer and rear bearing cone fitted on it into case, Reuse the used washer if they show normal tooth con- tact pattern when checked before disassembly.4WD SYSTEM {w2Fo]_3-4 Pinion height adjusting wash ‘oummy couian (98607703) DUMMY SHAFT (98607702) 9.174 9.177| Fig. 63 (3) Then, install preload adjusting spacer and washer, front bearing cone, DUMMY COLLAR, com. panion flange, washer and drive pinion nut. (4) Turn Cummy Shaft with hand to make it seated, and tighten drive pinion nut while measuring the pre- load with ‘spring balance as shown in the figure. Select preload adjusting washer and spacer so that the specified preload is obtained when nut is tight- ened to the specified torque. ‘8, Be careful not to give excessive preload. Fig. 55 Front & reer bearing proload For new bearing: 19.8 — 28.4 N(20— 2.9 kg, 44— 6.4 1b) {at companion flange bott hole For used bearing: 8,34 — 16.67 N (0.85 — 1.7 kg, 1.87 — 9.7510) at companion flange bolt hole Preload adjusting washers b. When tightening the drive pinion nut, lock Dummy Part No. Length mm {in} ‘Shaft with BLOCK as illustrated hers "383705200 2.59 (0.1020) 35716700 287 (02) 30575200, 2.585 (0.1004 365738200, 2.5 (2.0006) 365745200, 51 (00988) 36575200, 249 (0.0980 ousmy 243720 247 (00572 Shae 365775200 248 (0038) (388807702) 383765200 $3 (0.0957) 36373520 2 (00948) Shock 20960200 239 (00947 345016200, 737 (0.0983) ee 203825700 735 (0.0525) - 36635700 233 (0.0017 Fig. 54 383845200 2.31 {0,0909) Torque (Drive pinion nut): 167 — 196 N«m (17.0 — 20.0 kg-m, 123 — 145 Preload adjusting spacers ft-tt 7 [rennin yd Besee500 302 2219) 389685202 56.4 (2,220) 363686203 we (228 63604 cea 26) 63655205 7.02) 303605208 57.2 (2.262) 3) Adjusting drive pinion height Adjust drive pinion height with washer installed between rear bearing cone and the back of pinion gear. 23(IY Install Dummy Shaft, Collar and Gauge, as shown [fr ‘the figure, and apply the specified preload on the 4wWD SYSTEM Pinion height adjusting washers bearings. (Refer to 2.) Adjusting preload for front and it No. “Tickness ror i ‘rear bearings. 383496200, 3.09 (0.1217) ‘it this time, install 9 pinion height adjusting washer 383606200 3.12 (0.228) which is temporarily selected or the same as that used 312616200 7a (0.4240) oa "369526200 23.10 (01282) DUMMY SHAFT ‘GAUGE 399598200 321 (0.1268) puumry coven BEE07703 py HRE0P7O0 399546200 3:26 0.1276) 1383565200 327,(0.1267) o OR 33686200 3.30 (0.1288) so 365576200, 333101311), 389606200 3.96 (01323) a 388596200 230 (01336) 399606200 3:42 (0.1346) ight 33615200 3.46 (0.1368) er 393625200 348 (0.1370) Bs176| fig 66 309695200, 3 (01382) (2) Measure the clearance N between the end of Sie SeA0ee) Gauge and the end surface of Dummy Shaft by using 389066200 3.57 (0.1408) a thickness gauge. 380666200 360 (01817) Moke sure there is no clearance between the case and 383676200 3.3 (0.1420) Gauge. 389085200 3.00 (0.1441) (3) Obtain the thickness of pinion height adjusting ‘washer to be inserted from the following formula, and replace the temporarily installed washer with this one. T= To + N—(Hx 0.01) — 0.20 (mm) where T = Thickness of pinion height adjusting washer (mam) To = Thickness of washer temporarily inserted (enn) N = Reading of thickness gauge (mm) H = Figure marked on drive pinion head (Example of calculation) To = 2.20 + 1.20 = 3.40 mm N= 0.23mmH= +1, T = 3.40 + 0.23— 0.01 — 0.20 = 3.42 Result: Thickness = 3.42 mm Therefore use the washer 383605200. 4) Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into, position with INSTALLER. INSTALLER —+ (998177700) 33.178) Fig. 57 6) Insert drive pinion into differential carrier, install the previously selected preload adjusting spacer and washer. 6) Press-fit front bearing cone into case. 244WD SYSTEM [w2Fo} 3-4 10) Install self-locking nut with washer. INSTALLER (898680100) DUMMY COLLAR (398607703) WEIGHT (390780104) Bs.179| Fig, 58 : : Bs162| 7) Insert spacer, then press-fit pilot bearing with WEIGHT and INSTALLER. Fig. 61 Torque (Drive pinion nut): 167 — 186 Nem (17.0 — 20.0 kg-m, 123 — 145 —— ft-lb) 11) Assembling differential case Install side gears and pinion mate gears, with their iaeazemdbsmrant thrust washers and pinion mate shaft, into differential Pitot bearing ca Apply gear cil on both sides of the washer and on the side gear shaft before installing. Insert the pinion mate shaft into the differential case 83-180} by aligning the lock pin holes. Fig. 59 5 8) Fit a new oil seal with DRIFT. Ogee ea ee lips. (Refer to 1.) (2) Adjust the clearance as specified by selecting side gear thrust washer. ‘Special tool: Side gear back clearance: Peelers 0.1 — 0.2 mm (0.004 — 0.008 in) 9) Press-fi ion 8) Prost companion flange with INSTALLER 84 ay gar ehust washers Ponte. “Thickness mm (i Ba0448201 075 — 080 (00706 — 0916) ssauesa02 090 086 (00316 — 0.0336) 0045203 085 — 080 (0.0335 — 0.0368) INSTALLER (899876100) (8) Check the condition of rotation after applying oil ‘Companion flange to the gear tooth surfaces and thrust surfaces. (4) After driving in pinion shaft lock pin, stake the both sides of the hole to prevent pin from falling off. (6) Install drive gear on differential case. Torque (Drive gear bolt): 93 — 113 Nem (9.5 — 11.5 kg-m, 69 — 83 ft-lb) 9-181 Fig. 60 Tighten diagonally while tapping the bolt heads. 25i 4WD SYSTEM agg aw ye jefore installing si ing, measure the bearing Tal iby using a dial gauge, WEIGHT and GAUGE. "Standard bearing width: ("20,00 mm (0.7874 in) PE eee bate ee Sete eee Sot the dial gauge needle to zero, using a standard Bearing or block of specified height in advance. Gause WEIGHT (398237700) 4398227700). Sido bearing’ 9.163) Fig. 62 13) Press side bearing cone onto differential case with DRIFT and ADAPTER included in PULLER SET (399527700). DRIFT (398487700) ADAPTER (398497701 Fig. 63 14) Adjusting side bearing retainer shims {1) The drive gear backlash and side bearing preload ‘can be determined by the side bearing retainer shim thickness. (2) When replacing: differential case, differential carrier, side bearing and side bearing retainer, obtain the right and left retainer shim thickness from the following formulas. RE ¥ 53-105} Fig. 64 7, (let) = (A+ C+ G,—D)x001+ 0.76—E {mm} (B + D+ G,) x 0.01 + 0.76 —F (mm) Thickness of left and right side bearing retainer shim (mm) Number marked on differential car Number marked on differential cai 1 Difference of width of left and right side bearing from standard width 20.0 mm, expressed in 2 unit of 0.01 mm. For example, ifthe bearing measured width is 19.89 mm, value of E or F is as fol- lows. 20,00 — 19.89 = 0.11 (E or F) Number marked on side bearing retainer. T, (Right) Go G, Side bearing retainer -186| Fig. 65 Hf a number is not marked, regard it as zero. Use several shims to obtain the calculated thickness.3-4.-iw2co) ‘Atthe same time, measure the tuming resistance ‘of drive pinion. Compared with the resistance when Gifferential case is not installed, if the increase of the tance is not within the specified range, readjust fe bearing retainer shims. ein) "Turning resistance Increa: (0.1 — 0.6 Nem (1 — 6 kg-cm, 0.9 — §.2 in-tb) (8) Recheck drive gear-to-pinion backlash after read- justing shims. (9) Check the drive gear runout on its back surface, and make sure pinion and drive gear rotate smoothly. Limit of runout: 0.05 mm (0,0020 in) AWD SYSTEM 16) Assemble spindle into differenti with WRENCH. (Non-LSD model) ‘Special tool: WRENCH (925560000) and tighten bolt 17) After assembling circlip on spindle, set spindl differential and install by hitting it with a plastic ham. mer. (LSD model) 53-189] Fig. 68 18) Checking and adjusting tooth contact of drive gear. (1) Paint evenly both sides of three or four teeth on drive gear with red lead. Check the contact pattern after rotating drive gear several revolutions back and forth until definite contact pattern develops on drive gear. (2) When the contact pattern is incorrect, readjust according to the instructions given in “Tooth contact pattern”. Be sure to wipe off red lead completely upon com- pletion of adjustment. {3) After completing the above adjustment, install oil seal in side bearing retainer. ‘a. Use DRIFT (398437700) to press the oil seal into position. b, Apply chassis grease between the oil seal lips. (4) Install rear cover. Torque (Rear cover bol 19 — 25 Nem (1.9 — 2.6 kg-m, 14 — 19 ft-tb) Fig. 69 G: MOUNTING A 1) While raising rear differential with a transmist jack, insert rear drive shaft DOJ into differential spindle Tighten four self-locking nuts at the front and two locking nuts at the rear. 2) Position front member on body by passing it under parking brake cable, and secure to rear differential. ll other parts in the reverse order of dismount- 4) After installation fil differential carrier with gear oil to the upper plug level. Apply fluid packing to plug. Fluid packing: Three-bound 1205 or equivalent Oil capacity: 0.8 € (0.8 US qt, 0.7 Imp qt)4WD SYSTEM [W2Fo] 3-4 See ee Side bearing retainer shims Part No. Thickness ram (nh 1389475201 (0.20 (0.0078) 1300475202 (0.26 (0.0008) 3402476203 0.30 (0.0118) 302475204 0.40 (0.0157) 1389476208 (0.80 (0.0107) (3) Install the differential case ASSY into differential carrior in the reverse order of disassembling. (4) Fitthe selected shims and O-ring on side bearing retainer and install them on differential carrier with the arrow mark on the retainer directed as shown in Figure. Be careful that side bearing cup is not damaged by bearing roller. Example of calculation Ex.t A=5,B=6,C=3,D=3,6,=4,G, E = 0.10 mm, F = 0.16 mm Left side T= (A+ C+ G,—D)x0.01 + 0.76—E = G+ 34 4—3)x0.01 + 0.76 —0.10 = 0.09 + 0.76 — 0.10 = 0.75 mm The correct shims are as follows Thickness Q'ty 0.25 x 1 = 0.25 050 x 1 = 050 Total shim thickness = 0.75 mm 53-187 Right side Tr= (B+ D+ G,) x0.01 + 0.76—F (+ 3+ 1)x001 + 0.76—0.15 0.09 + 0.76 — 0.15, = 0.70 mm The correct shims are as follows Thickness Q'ty 020 x 1 = 0,20 050 x 1 = 0.50 Total shim thickness = 0.70 mm Ex.2 A= 2,8=3,C=0,0=3,G, E = 0.22 mm, F = 0.10 mm Left side T.= (A+ C+ G,—D)x0.01 + 0.76-E (2+ 0+ 2—3)x0.01 + 0.76 —0.22 = 0.01 + 0.76 — 0.22 = 0.65 mm The correct shims are as follows Thickness Q'ty Fig. 66 (6) Tighten side bearing retainer bolts. On vehicle with LSD, apply a coat of Three Bond 1215 {P/N 004403007) to threads. Torque (Side bearing retainer): 9 — 12 Nem (0.9 — 1.2 kg-m, 6.5 — 8.7 ft-lb) (6) Measure the drive gear-to-drive pinion backlash, is not within the specified range, cor- rect by decreasing the shim thickness on one side and increasing the shim thickness on the other side the same amount. Total shim thickness must be the same to maintain proper preload. Backlash: 0.10 — 0.20 mm (0.0039 — 0.0079 in) 0.25 x 1 0.25 030 x 1 0.30 Total shim thickness = 0.55 mm Right side Tae (B+ D+ G,) x0.01 + 0.76—F (3 + 3 + 3)x0.01 + 0.76 —0.10 = 0.09 + 0.76 — 0.10 = 0.75 mm The correct shims are as follows Thickness Q'ty 0.25 x 4 050 x 1 Total shim thickness B9-188) Fig. 67 27TOOTH CONTACT PATTERN Condition 4WD SYSTEM [waco] _3-4 Correct tooth contact. Tooth contact pattern slighty sited towards | toe under no toad rotation, Yoaded, contact pattern moves toward heel) Contact pattern ‘Adjustment Face contact Backlash is too large. Y i ‘This may causo noise and chipping st tooth > Increase thickness of ctv plalon adjusting washer in ordar to bring dive pin- En iShares al peeatabaue Kf? « —— eed ete aaa ‘ha may eae neon ape wn on fins pln ot rae ieee Tac eit ctll This may cause chipping at toe ends. | Adjust as for flenk contact. Tat ee [Contact area is small This may cause chipping at heal nds. > Adjust as for face contact, Fig. 70 29 83-1903-4 [F100} 4WD SYSTEM T TROUBLESHOOTING 4. Rear Differential ‘Symptom and possible cause Romecy "e Worn, scratched, oF Incorrectly seated front or side oil seal. [Repair or replace. ‘Seored, battered, of excessively worn sliding surface of compsn- | fon flange. ‘Clogged or damaged oir breather. (Clean, repair of replace. le or side retainer, oF incorrectly | Tighten bolts to specified torque. Replace O-ring. a leakage FFighton bolts to epecifiad torque. Replace gasket and apply liquid packing. tighten and apply liquid packing, "> Wear, damage or incorrectly fiting for spindle, side retziner and oll] Repair or replace. seal. Seizure ‘Getzed or damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should be repaired of replaced as requitod. ‘© Inauificiont backlash for hypoid geet. Readhust or replace. ‘Excessive preload for side, rear, or front bearing. Redgjust or replace, = Insufficient or improper oll used. Replace seized part and fil with specified ollto specified level Damage ‘Demaged parts shotld be replaced, nd also other parts should be thoroughly checked for any dofoct and should be repsired or replaced a8 required. ‘© Improper backlash for hypold gear. Replace. = Insufficient or excessive proload for side, rear, or front bearing. | Readjust of replace. Excossive becklash for difforertal goa Replace gear or trust washer. © Loose bolts and nuts such as drive gear bolt. Retighton. '@ Damage due to overioading. Replace. NNolsee when starting or shifting gears ‘Noloes may be chused.by diferontil ASSY, universal jolt, wheel bearing, etc: Find out what is actually making noise before diea sembly. "Excessive backlash for hypoid gear. Reedjust. 1 Excossive bacilach for differentia gear piace gear or twust washer, ‘ Ineufficiont preload for front or rear bearing. Readjust ‘Loose diive pinion nut Tighten to specified torque. “Loose bolts and nuts such as side bearing retainer attaching bok, | Tighten to specified torque,4WD SYSTEM (T200]_3-4 ‘Symptom and possible cause ‘Noises when cornering ‘© Damaged diferental gear, Replace, ‘© Excessive wear or damage of thrust washer. Replace, '& Broken pinion mato shaft. Replace, ‘= Seized or damaged side bearing Replace. Gear noises ‘Since noises from engine, mute, transmission, propeller shaft, whee! bearings, tre, and body ere sometimes mistaken for noises from dliforontia! ASSY, be caraful in checking thom. Inspection methods to locate noises include coasting, accelerating, crulsing, and jack- {ing up all four whsels. Perform these inspections according to condition of trouble. Whon listening to noises, shift goers into four wheel tive and fourth speed postion, tying to pick up only differential noise. = Improper tooth contact of hypold gear. Readjust oF replace hypold gear act '* Improper backlash for hypold gear. Readjust '* Scored or chipped teeth of hypoid gear, Replace typoid gear set. ‘© Seizod hypold gear. Replace hypoid gear set. '* Improper proload for front or rear bearings. Roadjust, 1 Seized, scored, or chipped front or rear bearing Replace. 1 Seized, 660104, or chipped side bearing, Replace. © Vibrating differential carver. Replace, 2. Propeller Shaft ‘Trouble and possible couse Vibration of propeler shaft Vibration is caused by propoller shaft during operation and is transfor vohicle speed. ‘© Worn or damaged universal joint. Replace. '* Unbslenced propollor shaft due to bend or dent Replace. ‘+ Loose installation of propeller shaft, Retighton ‘* Wein or damaged contr bowing and damaged center mounting | inc, rubbor ‘Tapping when starting and noise while eruising, caused by propeller hat. ‘© Worn or damaged universal joint Repl ‘© Worn spline of sleeve yore, Replace, ‘© Loose installation of propeller shaft. Ratighten. ‘© Loose installation of joint Replace, '* Worn ot demaged center bearing and damaged center mounting [ber Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper wheel alignment, etc. 31