M/T Differential Carrier Bearing Preload Adjustment

Special Tools Required Driver 07749-0010000 Attachment, 78 x 80 mm 07NAD-PX40100
Preload inspection tool
07YAJ-S3V0100
If any of the items listed below were replaced, the carrier bearing preload must be adjusted.

- Transmission housing
- Clutch housing
- Differential carrier
- Spacer
- Carrier bearing and outer race

1. Remove the oil seals from the transmission housing and clutch housing.

1. If you replaced the carrier bearing on the transmission housing side of the carrier, remove and discard the bearing outer race. Heat up the transmission housing to about 100 °C (212 °F) with a heat gun (A), then remove the bearing outer race (B), spacer (C), and 81 mm shim (D). Do not heat the housing in excess of 100 °C (212 °F).

1. If you replaced the carrier bearing on the clutch housing side of the carrier, remove and discard the beaing outer race. Heat up the clutch housing to about 100 °C (212 °F) with a heat gun (A), then remove the bearing outer race (B) and spacer (C). Do not heat the housing in excess of 100 °C (212 °F).

1. Install the 81 mm shim (A), spacer (B), and bearing outer race (C) in the transmission housing by using the special tools. (Use a new race if you replaced the bearing.) There should be no space between the race, spacer, and housing.

1. If you removed the bearing outer race from the clutch housing, use the special tools to install a new bearing outer race (A) and spacer (B). There should be no space between the race, spacer, and housing.

1. With the mainshaft and countershaft removed, install the differential assembly, and bolt the transmission and clutch housing together, and tighten the bolts to 44 N·m (4.5 kgf·m, 33 lbf·ft).
   NOTE: It is not necessary to use sealing agent between the housings for this adjustment.

1. Rotate the differential assembly in both directions to seat the tapered roller bearings.

1. At normal room temperature, measure the starting torque of the differential assembly by rotating it in both directions with the special tool and a torque wrench (A).

   Standard: | 3.43−4.51 N·m (35−46 kgf·cm, 30−40 lbf·in.)

1. If the carrier bearing preload is not within the standard, select a 81 mm thrust shim that will provide the correct preload:
   - Compare the bearing preload you got on the first try with the specified preload of 3.43−4.51 N·m (35−46 kgf·cm, 30−40 lbf·in.).
   - If the preload you measured was less than specified, subtract it from the specified preload.
   - If the preload you measured was more than specified, subtract it from the specified preload.
   For example, with a 2.50 mm (0.098 in.) thrust shim:

   (1) specified | 4.51 N·m (46 kgf·cm, 40 lbf·in.)
   − you got less | 2.55 N·m (26 kgf·cm, 23 lbf·in.)
   | 1.96 N·m (20 kgf·cm, 17 lbf·in.) less

   (2) you got more | 5.29 N·m (54 kgf·cm, 47 lbf·in.)
   − specified | 4.51 N·m (46 kgf·cm, 40 lbf·in.)
   | 0.78 N·m (8 kgf·cm, 7 lbf·in.) more

   NOTE: Each shim size up or down from standard makes about 0.3−0.4 N·m (3−4 kgf·cm, 2.6−3.5 lbf·in.) difference in preload.
   In example (1), your preload was 1.96 N·m (20 kgf·cm, 17 lbf·in.) less than standard, so you need a thrust shim five sizes thicker than standard (try the 2.65 mm (0.104 in.) 81 mm thrust shim, and recheck).
   In example (2), your preload was 0.78 N·m (8 kgf·cm, 7 lbf·in.) more than standard, so you need a thrust shim two sizes thinner (try the 2.44 mm (0.096 in.) 81 mm thrust shim, and recheck).
   81 mm Shim

   | Part Number | Thickness
   --- | --- | ---
   A | 41438-PYZ-000 | 2.05 mm (0.081 in.)
   B | 41439-PYZ-000 | 2.08 mm (0.082 in.)
   C | 41440-PYZ-000 | 2.11 mm (0.083 in.)
   D | 41441-PYZ-000 | 2.14 mm (0.084 in.)
   E | 41442-PYZ-000 | 2.17 mm (0.085 in.)
   F | 41443-PYZ-000 | 2.20 mm (0.087 in.)
   G | 41444-PYZ-000 | 2.23 mm (0.088 in.)
   H | 41445-PYZ-000 | 2.26 mm (0.089 in.)
   J | 41446-PYZ-000 | 2.29 mm (0.090 in.)
   K | 41447-PYZ-000 | 2.32 mm (0.091 in.)
   L | 41448-PYZ-000 | 2.35 mm (0.093 in.)
   M | 41449-PYZ-000 | 2.38 mm (0.094 in.)
   N | 41450-PYZ-000 | 2.41 mm (0.095 in.)
   P | 41451-PYZ-000 | 2.44 mm (0.096 in.)
   Q | 41452-PYZ-000 | 2.47 mm (0.097 in.)
   R | 41453-PYZ-000 | 2.50 mm (0.098 in.)
   S | 41454-PYZ-000 | 2.53 mm (0.100 in.)
   T | 41455-PYZ-000 | 2.56 mm (0.101 in.)
   U | 41456-PYZ-000 | 2.59 mm (0.102 in.)
   V | 41457-PYZ-000 | 2.62 mm (0.103 in.)
   W | 41458-PYZ-000 | 2.65 mm (0.104 in.)
   X | 41459-PYZ-000 | 2.68 mm (0.106 in.)
   Y | 41460-PYZ-000 | 2.71 mm (0.107 in.)
   Z | 41461-PYZ-000 | 2.74 mm (0.108 in.)
   AA | 41462-PYZ-000 | 2.77 mm (0.109 in.)
   AB | 41463-PYZ-000 | 2.80 mm (0.110 in.)
   AC | 41464-PYZ-000 | 2.83 mm (0.111 in.)
   AD | 41465-PYZ-000 | 2.86 mm (0.113 in.)
   AE | 41466-PYZ-000 | 2.89 mm (0.114 in.)
   AF | 41467-PYZ-000 | 2.92 mm (0.115 in.)
   AG | 41468-PYZ-000 | 2.95 mm (0.116 in.)
   AH | 41469-PYZ-000 | 2.98 mm (0.117 in.)
   AJ | 41470-PYZ-000 | 3.01 mm (0.119 in.)
   AK | 41471-PYZ-000 | 3.04 mm (0.120 in.)
   AL | 41472-PYZ-000 | 3.07 mm (0.121 in.)
   AM | 41473-PYZ-000 | 3.10 mm (0.122 in.)
   AN | 41474-PYZ-000 | 3.13 mm (0.123 in.)
   AP | 41475-PYZ-000 | 3.16 mm (0.124 in.)

1. Once the carrier bearing preload is correct, disassemble the transmission housing, and install new oil seals in the differential.

1. Reassemble the transmission.

1. Reinstall the transmission.