Limited Slip Differential

Transcription

TUNDRA (UCK30, 40 and
VCK30, 40)
Part Number: 00646-41301-100
Section I. Installation Preparation
Kit Contents
Qty
1
1
Description
LSD Differential
Lubricant Additive
Special Tools Required
Regular Tools
Toyota
Special
Service Tools (or
equivalent)
Weight: 15.9 lbs
#
1
2
LS-TUN-001-A
Part Number
00602-41301-101
Vehicle Lift
(recommended)
Vise Grips, C-Clamp, or
similar tool that self-holds
Paint Marker or Grease
Pencil
Plastic Hammer
Old Pan for Heating Ring
Gear (in boiling water)
Thread Lock (Part No.
08833-00100, Three Bond
1360K or equivalent)
Dial Indicator
Micrometer
09504-22011
09950-40011
09950-60010
09950-70010
General Applicability
2000 and newer Tundra
Legend
STOP: Damage to the vehicle may occur.
proceed until process has been completed.
For parts, supplies, and tools required, refer to the Toyota
Repair Manual. With a few exceptions, installation of the
limited slip differential is the same as the remove and
replace procedure described in the manual.
The
exceptions are noted in these instructions.
Do not
OPERATOR SAFETY: Use caution to avoid risk of
injury.
CRITICAL PROCESS: Proceed with caution to ensure
a quality installation. These points will be audited on a
completed vehicle installation.
GENERAL PROCESS: This highlights specific
processes to ensure a quality installation. These
points will be audited on a completed vehicle
installation.
TOOLS & EQUIPMENT: Special tools are needed for
this step.
Recommendations
We recommend that you lift the vehicle for the installation.
Additional Supplies
If you have an older vehicle or feel you made need new gaskets
and/or seals during installation, purchase a Rear Differential Carrier
Gasket Kit (Part No. 04412-34011) from a Toyota Dealer.
Rev: A © TRD 12/06/01
Page 1 of 17
VCK30, 40)
LS-TUN-001-A
Section II. Vehicle Disassembly Procedure
Please follow the Toyota Repair Manual instructions
steps 1 through 17 (beginning on page SA-95) to
remove the factory differential carrier assembly. The
notes in this section will highlight specific points.
Figure 1 shows an exploded view of the major parts
you will be working with.
Figure 1.
1. Lift the vehicle (a chassis lift is recommended)
and leave the parking brake off (Figure 2).
Figure 2.
Rev: A © TRD 12/06/01
Page 2 of 17
VCK30, 40)
LS-TUN-001-A
2. Drain the differential case (Figure 3).
Figure 3.
3. Remove both rear wheels and brake drums.
Note the use of bolts (8 x 1.25) to push the drum
away from the hub in Figure 4.
Figure 4.
Rev: A © TRD 12/06/01
Page 3 of 17
VCK30, 40)
LS-TUN-001-A
4. Pinch the flexible brake line above the differential
housing just upstream of the “T” where the solid
lines start (Figure 5). Use tape or cloth to prevent
damage to the flexible line.
5. Remove the brake lines (including the parking
brake cord) from the drums and plug them
promptly to minimize fluid loss (this will make
bleeding them at the end much easier).
Figure 5.
6. Remove the four (4) 14mm nuts that hold the
hubs to the rear axle housing (Figure 6).
Figure 6.
Rev: A © TRD 12/06/01
Page 4 of 17
VCK30, 40)
LS-TUN-001-A
7. Pull the half shafts and hubs out and set on
ground (Figure 7). Have an assistant hold a rag
against the shaft as it is removed to keep the
work area clean.
NOTICE: Take care to pull the shaft straight out
and not rub against the oil seal to prevent
damage which may cause leaks after
reassembly.
Figure 7.
8. Place matchmarks on the differential
propeller shaft flanges (Figure 8).
and
Figure 8.
Rev: A © TRD 12/06/01
Page 5 of 17
VCK30, 40)
LS-TUN-001-A
9. Remove the 4 nuts, bolts, and washers that
connect the propeller shaft to the differential
carrier (Figure 9). Detach the propeller shaft from
the rear differential carrier. On 2WD models,
remove the shaft retainer before detaching the
propeller shaft.
Figure 9.
10. Remove the 10 nuts that hold the rear differential
carrier to the rear axle housing (Figure 10).
Remove the rear differential carrier.
Check that the rear differential carrier has been
completely drained and that the flow of oil has
stopped.
DO NOT damage the installation surface.
Figure 10.
Rev: A © TRD 12/06/01
Page 6 of 17
VCK30, 40)
LS-TUN-001-A
11. Your stock unit should look like that in Figure 11.
12. Remove the gasket from the rear axle housing.
Section III. Differential Case Removal
steps 11-12, 15, and 17-18 (beginning on page SA98) to remove the factory differential case. The notes
in this section will highlight specific points.
Figure 11.
1. Place matchmarks on the bearing cap and
differential carrier (Figure 12).
2. Remove the 4 bolts and bearing cap.
Figure 12.
Rev: A © TRD 12/06/01
Page 7 of 17
VCK30, 40)
LS-TUN-001-A
3. Using the Special Service Tool (SST) 0950422011 and a plastic hammer, remove the 2 side
bearing plate washers (Figure 13).
HINT: Measure the plate washer thickness and write
it down.
4. Remove the differential case with the bearing
outer races from the carrier.
HINT: Tag the bearing outer races to show the
location for reassembling.
5. Remove the drive pinion from differential carrier.
Figure 13.
6. Remove the 12 bolts that secure the ring gear
(Figure 14).
7. Using a plastic hammer, tap on the ring gear to
separate it from the differential case.
Figure 14.
8. Using the SSTs (09950-40011 & 09950-60010),
remove the 2 side bearings from the differential
case (Figure 15).
HINT: Fix the claws of the SST to the notch in the
differential case.
Figure 15.
Rev: A © TRD 12/06/01
Page 8 of 17
VCK30, 40)
LS-TUN-001-A
Section IV. Differential Case Assembly
steps 1-4, 8-13 (beginning on page SA-101) to install
the new limited slip differential case. The notes in
this section will highlight specific points.
1.
Using the SSTs (09950-60010 & 09950-70010)
and a press, install the 2 side bearings into the
differential case (Figure 16).
2.
Clean the contact surfaces of the differential case
and ring gear.
Figure 16.
3.
Heat the ring gear by placing in boiling water
(Figure 17).
4.
Carefully take the ring gear out of the boiling
water.
5.
After the moisture on the ring gear has
completely evaporated, quickly install the ring
gear to the differential case.
6.
After the ring gear has cooled significantly, torque
the set bolts to which the thread lock has been
applied.
Thread lock: Part No. 08833-00100, Three
Bond 1360K or equivalent.
Torque: 92 ft-lbf
7.
Place the 2 bearing outer races on their
respective bearings. Make sure the right and left
races are not interchanged.
8.
Install the differential case into the carrier and
install the plate washers to where there is no play
in the bearing.
9.
Align the matchmarks on the bearing cap and the
carrier.
10. Install and torque the 4 bolts to 83 ft-lbf.
Rev: A © TRD 12/06/01
Page 9 of 17
Figure 17.
VCK30, 40)
LS-TUN-001-A
11. Using a dial indicator, measure the runout of the
ring gear (Figure 18).
Maximum runout: 0.0020 in.
12. Remove the bearing cap.
Figure 18.
13. Install the plate washer on the ring gear back side
(Figure 19).
HINT: Make sure that the ring gear has backlash.
Figure 19.
Rev: A © TRD 12/06/01
Page 10 of 17
VCK30, 40)
LS-TUN-001-A
14. Tap on the ring gear with a plastic hammer so
that the washer fits to the bearing (Figure 20).
Figure 20.
15. Using a dial indicator, while holding the
companion flange, measure the ring gear
backlash (Figure 21).
Backlash: 0.006 – 0.010 in. (do not use the
number in the manual)
Figure 21.
16. Select a plate washer for the back side ring gear
so that the backlash is within the required range
(Figure 22).
Figure 22.
Rev: A © TRD 12/06/01
Page 11 of 17
VCK30, 40)
LS-TUN-001-A
17. Select a ring gear teeth side plate washer so that
there is no clearance between the outer race and
case (Figure 23).
18. Remove the 2 plate washers that were selected
in steps 16 and 17 and the differential case.
19. Install the plate washer into the ring gear back
side of the carrier.
Figure 23.
20. Place the other plate washer onto the differential
case together with the outer race, and install the
differential case with the outer race into the
carrier (Figure 24).
21. Tap on the ring gear with a plastic hammer so
that the washers fit to the bearing.
Figure 24.
22. Using a dial indicator, while holding the
companion flange, measure the ring gear
backlash (Figure 25).
If the backlash is not within the specified value, adjust
it by either increasing or decreasing the thickness of
washers on both sides by an equal amount.
HINT: There should be no clearance between the
plate washer and the case.
Make sure that there is a ring gear backlash.
Figure 25.
Rev: A © TRD 12/06/01
Page 12 of 17
VCK30, 40)
LS-TUN-001-A
23. Remove the ring gear teeth side plate washer
and using a micrometer, measure the thickness
(Figure 26).
24. Using the backlash as a reference, install a new
washer (0.0024 – 0.0035 in.) thicker than the
washer removed.
HINT: Select a washer which can be pressed in 2/3 of
the way with your finger.
25. Using a plastic hammer, install the plate washer
Figure 26.
26. Recheck the ring gear backlash (Figure 27).
If the backlash is not within the specified value, adjust
it by either increasing or decreasing the thickness of
washers on both sides by an equal amount (see
Table 1 on the next page).
HINT: The backlash will change by about 0.0008 in.
corresponding to 0.0012 in. change in the plate
washer.
27. Reinstall the bearing cap (see steps 15 – 16).
28. Coat 3 or 4 teeth at three different positions on
the ring gear with red lead primer.
29. Hold the companion flange firmly and rotate the
ring gear in both directions.
30. Inspect the teeth pattern (see page 15).
Rev: A © TRD 12/06/01
Page 13 of 17
Figure 27.
VCK30, 40)
Rev: A © TRD 12/06/01
Page 14 of 17
LS-TUN-001-A
VCK30, 40)
Rev: A © TRD 12/06/01
Page 15 of 17
LS-TUN-001-A
VCK30, 40)
Section V. Differential Case Installation
step 1 (beginning on page SA-110) to install the new
limited slip differential case. The notes in this section
will highlight specific points.
1.
Install a new gasket.
2.
Install the differential carrier assembly (with the
limited slip differential inside) with 10 washers
and nuts.
NOTICE: Be careful not to damage the installation
surface.
Torque: 54 ft-lbf
Section VI. Reassembly of Vehicle
steps 2 through 4 (beginning on page SA-110) to
install the new limited slip differential case. The notes
in this section will highlight specific points.
1. Align the matchmarks on the propeller shaft and
differential flanges and connect the flanges with
the 4 bolts, washers and nuts.
2. Torque the 4 bolts to 54 ft-lbf.
3. Install new O-Ring to rear axle housing.
4. Install rear axle shaft assemblies. Torque to 51
ft-lbf.
5. Connect brake lines and parking brake cable.
Torque to 11 ft-lbf.
6. Install a new gasket and replace the brake drums
and the wheels.
Rev: A © TRD 12/06/01
Page 16 of 17
LS-TUN-001-A
VCK30, 40)
7. Replace the Drain Plug and tighten to 49 ft-lbs.
Remove the Filler Plug. Pour all of the limited
slip differential lubricant additive into the
differential. Fill the differential with Hypoid Gear
Oil API GL-5
Oil Viscosity:
Above 0ºF: SAE 90
Below 0ºF: SAE 80W or 80W – 90
Capacity:
2WD: 3.33 US quarts
4WD: 3.12 US quarts
Stop filling when the level of the oil reaches within
0.200” of the bottom of the filler hole. Replace
the Filler Plug and tighten to 49 ft-lbs.
8. Bleed rear brake lines.
Rev: A © TRD 12/06/01
Page 17 of 17
LS-TUN-001-A

Limited Slip Differential

Transcription

Similar documents

Free Running Differential (FRRD®)

brabus 190e 3.6s

special driveline parts for chain drive cars d sport racer c sport racer

Gearless Locker 2 Suzuki

Linearity of the Schrödinger Equation Linearity of the Schrödinger

Differential Equations and Transform Methods Module code: EE 206

XGames.ESPN.go.com

Spare Parts Catalogue