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cage
Mcasure the clearance between
the
rear
face of thc side
gear
and the differential
cage
as
shown
in
Fig
G
ll
and if
necessary
use
a
tluust
washer
which will
given
a
clearance of
0 1
0 2mm
0 004
0 008
in
Fit
the
pinion
shaft lock
pin
and
secure
it
by caulking
with
a
punch
Lubricate the
gear
teeth
and check
the gear
for freedom of rotation
Install the
crown
wheel in
the
differential
cage
and insert
the bolts
with
new
lock
straps Tap
the head of each bolt
lightly
and
tighten
the bolts in
a
diagonal pattern
to
a
torque
reading
of 7 0
8 0
kgm
51
58Ib ft
Measure the width of the side
bearings
before
installing
them
Place
a
weight
of 2 5
kg
5
5 1 b
on
the
bearings
and check the nominal width which should be
20mm 0 787 in
Press
the
side
bearings
into the differential
cage
Adjustment
of drive
pinion
preload
This
adjustment
is carried
out
without
fitting
the oil seal
Press the front and
rear
bearing
outer
races
into the gear carrier
and fit the
pinion height adjusting
washer
Fig
G 12
the
shims
and the
rear
bearing
inner
race
onto
a
dummy
shaft
special
tool ST 31
120000
The old washers
and
shims
can
be
re
used if the tooth
contact
pattern
was
found
to be correct
on
the pre
dismantling
check Fit the drive
pinion bearing
spacer
the washer
ans
special
collar 5T 312140000
or
5T 31500000
and
the drive
flange
on
to
the
dummy
shaft
Tighten
the drive
pinion
nut to
a
torque
reading
of
17
20
kgm 123
145 Ib
ft
Measure
the drive
pinion bearing
pre
load and select washers
and
spacers
to
give
a
pre load
of 7 1 0
kg
cm
6
9Ib in
with
new
bearings
or
3
6
kg
cm
2
6
5
Ib in
with used
bearings
Adjusting
spacers
are
available in
lengths
of 56 2
57 2
mm
2 2126
2
2520 in and
adjusting
washers
in thicknesses of
59
2 31
mm
0 1020
0 0909
in
Adjustment
of
pinion height
The
pinion height
or
distance
of the face of the
pinion
to
the axis of
the
crownwheel is
adjusted by
the thickness of the
adjusting
washer behind the drive
pinion
gcar
The drive
pinion
has
a
tolerance mark etched
on
its face
this tokrance
is
accompanied by
a
or
sign
to
show the
deviation from the nominal dimension Thc
plus sign
indicates
that
the nominal distance
must
be increased
and
the minus
sign
that it
mllst
be decreased The tolerances
are
shown in
Fig
G I3
The
pinion height
can
be
adjusted using
the
original
adjusting
washer
and shims between the
rear
bearing
cone
and
the
drive
pinion
Install
the
setting
gauge
5T 31210000
on
the
carrier with the
dummy pinion
installed
Sce
Fig
G 14
Measure the clearance between the head of
the
dummy
shaft and the
tip
of the
setting
g wge
using
a
feeler gauge
as
shown in
Fig
G 15 The clearance
is
also shown
at
the
point
T
in
Fig
G 14 The
required
thickness of the
adj lsting
washer
can
be obtained
using
the
following
formula
S
W
T
H
x
0 01
0 20
Where
W
thickness of inserted shims and washers
T
Measured thickness
H
Figure engraved
on
pinion
head
o
S
Required
thickn
ss
of washers and shims
A
typical example
is
given
below
w
20
1 20
T
H
S 340
0 24
2
x
0 01
0 20
3
4 0
mm
0 24
mm
3
4 6
mm
An
adjusting
washer
rrlust
be selected which is
nearest in
thickness
to
the value of 3
46mm
Adjusting
washers
are
available
in thicknesses of 3 09mm
0
01217 in
to
3 66m
0 1441 in
for
the
l800cc
models and in thicknesses of
O
2
and
2 4 mm
0 787
0 866 and 0 945 in
for the 1400 and 1600
cc
models
Fit the selected
adjusting
washer and shims
to
the drive
pinion
and
press
on
the
rear
bearing
inner
race
Install the drive
pinion
into the differential carrier
together
with the
bearing
spacer and
washer
the front
bearing
inner
race
and the
front
bearing pilot
spacer
Fit the drive
flange
and washer
on
the drive
pinion
and
secure
them with the
pinion
nut
Tighten
the
nut to
a
torque
reading
of 17 20
kgm 123
145Ib ft
SIDE BEARING SHIMS
Selecting
The side
bearing
pre
load
must
be
adjusted
with selected
shims
if
the
differential
carrier
the
cage
the side
bearings
or
the
bearing
covers
have been renewed
The
required
thickness of the shims
can
be obtained
using
the
following
formula and
referring
to
Fig
G l 5
T1
left side
bearing
A
C
GI
D
E
H
x
0 01
0 76
T2
right
side
bearing
B
D
G2
F
H
x
0 01
0 76
Where
A
B
C
D
E
F
The
figure
on
the differential carrier
The
figure
on
the differential
cage
The
differences in width of the left
or
right
hand
bearings against
the nominal width of 20 0mm
0 7874 in
given
in units of 1
100
mm
Gl
G2
H
The
figure
on
the side
cover
The
figure
on
the crownwheel
The
A
B C D G and
H
figures
indicate
the
dimensional
variations in units of 1
100
mm
fr Jm
the standard
measurement
An
example
of the calculations
to
decide the thickness of shim
required
is
given
below
Where
A
I
B
2
C 2 D
1 GI
3 G2
1
E O Olmm F
O 02mm H
Left side
bearing
Tl
A
C
G 1
D
H
x
0 01
0 76 E
I
3
1
2
x
0 01
0 76
0 01
0 8mm
Right
side
bearing
T2
B
D
G2
H
x
0 01
0 76
F
2
I
I
2
x
0 01
0 76
0 02
0 8mm
Page 67
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