Check the projection (A) of the knock pins.
NOTE: When attached on the converter case side, install them on the drive pinion retainer side.

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Specification:

8.0 - 9.0 mm (0.31 - 0.35 in)

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Select the drive pinion washer.

Measure the dimension "A" of a new taper roller bearing (front) inner race.

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Measure the dimension "B" of a new taper roller bearing (rear) inner race.

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Measure the dimension "C" of the drive pinion spacer.

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Place the drive pinion retainer on the surface plate, and set the taper roller bearing (rear) inner race to the taper roller bearing (rear) outer race.
NOTE: Be careful not to tilt the taper roller bearing (rear) inner race when setting.

Measure the height "H1" from the end face of the taper roller bearing (rear) inner race to the surface plate.

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Set the taper roller bearing (front) inner race to the taper roller bearing (front) outer race.
NOTE: Be careful not to tilt the taper roller bearing (front) inner race when setting.

Using the ST, measure and record the height "H2" from the ST end face to the taper roller bearing (front) inner race.

Preparation tool:

ST: GAUGE (499575400)

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Using the following calculation, calculate an appropriate thickness "T1" of the drive pinion washer.
NOTE: Adjust using 1 - 3 pieces.

T1 = H1 - (A + B + C + H2 - 15 mm (0.6 in))

T1	Drive pinion washer thickness (mm (in))
H1	Measured value (mm (in)) of step (5)
A	Measured value (mm (in)) of step (1)
B	Measured value (mm (in)) of step (2)
C	Measured value (mm (in)) of step (3)
H2	Measured value (mm (in)) of step (7)
15 mm (0.6 in)	Thickness of ST (GAUGE)

Select the drive pinion shim.

Using the ST, measure the height "H3" from the ST end face to the drive pinion retainer mating surface.

Preparation tool:

ST: GAUGE (499575400)

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Using the following calculation, calculate the height "H4" from the transmission case mating surface of the converter case to the drive pinion retainer mating surface.

H4 = H3 - 15 mm (0.6 in)

H4	Height (mm (in)) from the transmission case mating surface of the converter case to the drive pinion retainer mating surface
H3	Measured value (mm (in)) of step (1)
15 mm (0.6 in)	Thickness of ST (GAUGE)

Place the converter case on the surface plate.

Measure the inner diameter "D1" of the differential side retainer installation hole of the converter case.

NOTE: Perform the measurement at the contact surface of the side bearing outer race.

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Using the following calculation, calculate the radius "R" of the differential side retainer installation hole.

R = D1/2

R	Differential side retainer installation hole radius (mm (in))
D1	Measured value (mm (in)) of step (4)

Prepare a proper round bar, and measure its diameter at several locations.
Mark locations with the same measured values and refer to the values as "D2".

Set the marked location on the installation hole of the differential side retainer, and measure the height "H5" from the top end of the other marked location to the surface plate.

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Using the following calculation, calculate the height "H6" from the bottom end of the differential side retainer installation hole to the transmission case mating surface of the converter case.

H6 = H5 - D2

H6	Height (mm (in)) from the bottom end of the differential side retainer installation hole to the transmission case mating surface of the converter case
H5	Measured value (mm (in)) of step (8)
D2	Measured value (mm (in)) of step (7)

Using the following calculation, calculate the distance "S" from the center of the front differential to the transmission case mating surface of the converter case.

S = R + H6

S	Distance (mm (in)) from the center of the front differential to the transmission case mating surface of the converter case
R	Calculated value (mm (in)) of step (5)
H6	Calculated value (mm (in)) of step (9)

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Using the following calculation, calculate an appropriate thickness "T2" of the drive pinion shim.
NOTE: Adjust using 1 - 3 pieces.

T2 = (S - H4 + H2 - 15 mm (0.6 in)) - 90.8 mm (3.57 in)

T2	Drive pinion shim thickness (mm (in))
S	Calculated value (mm (in)) of step (10)
H4	Calculated value (mm (in)) of step (2)
H2	Measured value (mm (in)) of assembly step 2. (7)
15 mm (0.6 in)	Thickness of ST (GAUGE)
90.8 mm (3.57 in)	Ideal distance from the front differential center to the drive pinion end surface

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Set the drive pinion shim.

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Press-fit the taper roller bearing (front) inner race using the ST1, ST2 and a press.
Preparation tool:

ST1: INSTALLER (899580100)

ST2: EXTENSION DRIVE SHAFT (927130000)

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Install the drive pinion spacer and drive pinion washer.
NOTE: Install the O-ring after checking and adjusting the tooth contact of hypoid gear set.

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Set the drive pinion.
CAUTION: Be careful not to damage the oil seal.

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