REAR DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY


  1. INSTALL FRONT BEARING OUTER RACE


    1. A01CGR4E01

      Using SST and a press, press in the front bearing outer race onto the bearing cage.

      SST
      09518-36020

      Tech Tips

      Apply gear oil to the front bearing outer race.

  2. INSTALL REAR BEARING OUTER RACE


    1. A01CIRWE01

      Using SST and a press, press in the rear bearing outer race onto the bearing cage.

      SST
      09223-78010

      Tech Tips

      Apply gear oil to the rear bearing outer race.

  3. INSTALL PILOT BEARING INNER RACE


    1. A01CGNXE01

      Using SST and a press, press in the pilot bearing inner race onto the differential drive pinion.

      SST
      09316-60011   ( 09316-00011, 09316-00071 )

      Tech Tips

      Apply gear oil to the inner race.

    2. A01CI4V

      Using a snap ring expander, install a new snap ring in the groove on the differential drive pinion tip.

      Note

      When installing the snap ring, use a cloth or equivalent to prevent the snap ring from flying off.

  4. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01CGUXE01

      Using SST and a press, install the rear drive pinion rear tapered roller bearing onto the differential drive pinion.

      SST
      09315-00022

      Tech Tips

      Apply gear oil to the inner race.

  5. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01CGSL

      Install the rear differential drive pinion bearing spacer.

  6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01CJ04E01

      Using SST and a press, install the differential drive pinion bearing cage and front tapered roller bearing onto the differential drive pinion.

      SST
      09316-60011

  7. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01CHCC

      Install the rear drive pinion companion flange sub-assembly and rear drive pinion nut to the drive pinion. Hold the drive pinion companion flange sub-assembly in a vise with aluminum plates in between.

    2. A01CHFM

      Using a deep socket wrench (41 mm), tighten the rear drive pinion nut.

      Torque:
      435 N*m  { 4437 kgf*cm, 321 ft.*lbf }
    3. A01CHP4

      Using a torque wrench, measure the preload at the rear drive pinion nut part.

      Preload:
      New bearing Reused bearing

      1.48 to 1.96 N*m

      (15 to 20 kgf*cm, 13 to 17 in.*lbf)

      0.98 to 1.47 N*m

      (10 to 15 kgf*cm, 9 to 13 in.*lbf)

      Note


      • Do not install an oil seal before preload measurement.

      • When either of the bearings is new, use the preload for a new bearing.

    4. A01CGSL

      When the measured value is not within the specified range, select the drive pinion bearing spacer thickness to adjust the preload.

      Spacer thickness:
      Part No. Thickness
      41231-37420 14.400 mm (0.5669 in.)
      41231-37430 14.425 mm (0.5679 in.)
      41231-37440 14.450 mm (0.5689 in.)
      41231-37450 14.475 mm (0.5699 in.)
      41231-37460 14.500 mm (0.5709 in.)
      41231-37470 14.525 mm (0.5718 in.)
      41231-37480 14.550 mm (0.5728 in.)
      41231-37490 14.575 mm (0.5738 in.)
      41231-37500 14.600 mm (0.5748 in.)
      41231-37510 14.625 mm (0.5758 in.)
      41231-37520 14.650 mm (0.5768 in.)
      41231-37530 14.675 mm (0.5778 in.)
      41231-37540 14.700 mm (0.5787 in.)
      41231-37550 14.725 mm (0.5797 in.)
      41231-37560 14.750 mm (0.5807 in.)
      41231-37570 14.775 mm (0.5817 in.)
      41231-37580 14.800 mm (0.5827 in.)
      41231-37590 14.825 mm (0.5837 in.)
      41231-37600 14.850 mm (0.5846 in.)
      41231-37610 14.875 mm (0.5856 in.)

  8. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01CIUD

      After preload adjustment, remove the companion flange sub-assembly and use a brass bar and hammer to tap in a new rear differential carrier oil seal into the differential drive pinion bearing cage.

      Note

      Tap the oil seal uniformly to drive it in.

    2. Apply MP grease to the oil seal lip.

  9. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR


    1. A01CGXXE01

      Using SST and a press, install a new rear differential dust deflector to the rear drive pinion companion flange sub-assembly.

      SST
      09950-60010   ( 09951-00610 )
      09950-70010   ( 09951-07100 )
      09527-17011

      Note

      Perform this procedure only when the dust deflector has been removed.

  10. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01CHFM

      Apply MP grease to the rear differential dust deflector lip.

    2. Install the rear drive pinion companion flange sub-assembly, and tighten a new rear drive pinion nut using a deep socket wrench (41 mm).

      Torque:
      435 N*m  { 4437 kgf*cm, 321 ft.*lbf }
    3. A01CHP4

      Using a deep socket wrench (41 mm) and torque wrench, measure the drive pinion preload (starting torque) with the oil seal installed.

      Tech Tips

      The measured value should be used to calculate the side bearing preload after installing the drive pinion assembly to the differential carrier.

    4. A01CI31E01

      Using SST and a hammer, stake a new rear drive pinion nut completely while aligning the 2 shaft grooves.

      SST
      09930-00010

      Note


      • Stake the nut completely as shown in the illustration.

      • Ensure that there is no crack on the staked part of the nut.

  11. INSTALL O-RING


    1. Using a scraper, clean off dust on the connecting surfaces of the bearing cage, differential carrier and shim(s).

      Note

      Be careful not to damage the installation surface.

    2. Apply MP grease to a new O-ring.

    3. Install the O-ring to the differential drive pinion bearing cage.

      Note

      Be careful not to damage the O-ring.

  12. INSTALL DIFFERENTIAL CASE


    1. A01CH1L

      Apply hypoid gear oil to the sliding surfaces of the rear differential side gear thrust washer, rear differential side gear and differential case LH.

    2. Install the rear differential side gear thrust washer on the rear differential side gear.

    3. Apply hypoid gear oil to the sliding surfaces of the rear differential spider, rear differential pinions, rear differential side gear thrust washers and differential case LH.

    4. A01CGS7

      Install the 4 rear differential pinions and thrust washers to the spider.

    5. Install the spider with the differential pinions and thrust washers on the differential case LH.

    6. A01CIOG

      Install the rear differential side gear and thrust washer to the differential case RH.

    7. Apply gear oil to each part.

    8. A01CHTEE01

      Align the matchmarks on the differential case LH and differential case RH.

    9. Using a press, fix the differential case.

    10. A01CI7X

      Apply adhesive to the threads of the 8 bolts and install them.

      Adhesive
      Three Bond 1360K or equivalent
      Torque:
      190 N*m  { 1938 kgf*cm, 141 ft.*lbf }

  13. INSTALL DIFFERENTIAL RING GEAR


    1. A01CIP6E01

      Clean the contact surfaces of the differential case and ring gear.

    2. Clean the differential ring gear set bolt hole.

    3. Heat the ring gear approx. 100°C (212°F) in boiling water.

      CAUTION:

      Use thick gloves to protect your hands as the ring gear is hot.

    4. Carefully take the ring gear out of the boiling water.

    5. Hold the differential case in a vise with aluminum plates in between.

      Note

      Do not overtighten the vise.

    6. A01CHZLE01

      Align the matchmarks on the ring gear and the differential case LH.

    7. Apply adhesive to the threads of the 16 bolts and install them.

      Adhesive
      Three Bond 1360K or equivalent
      Torque:
      182 N*m  { 1855 kgf*cm, 134 ft.*lbf }

  14. INSTALL SIDE BEARING INNER RACE


    1. A01CIBME01

      Using SST and a press, install the 2 side bearing inner races to the differential case.

      SST
      09950-60010   ( 09951-00640, 09951-00650 )

      Note

      Be careful not to apply load to the bearing retainers when installing.

  15. INSTALL PILOT BEARING OUTER RACE


    1. A01CI9F

      Install the pilot bearing outer race with the 2 retainers, bolt and a new nut.

      Torque:
      22 N*m  { 225 kgf*cm, 16 ft.*lbf }

  16. INSPECT CONICAL DISTANCE


    1. A01CJ9HE01

      Using SST, measure the depth from the side bearing mounting surface to the drive pinion tip (this depth is called the conical distance).

      SST
      S0964-01022
      Standard
      27 mm (1.063 in.)

      Note


      • Before installing the differential drive pinion, record the machining error dimension stamped at the pinion tip and use it for calculation of the conical distance.


      • The conical distance is the standard dimension at the time of adjustment of the tooth contact of the drive pinion and ring gear, and the best tooth contact is obtained when setting is done with this dimension. For reasons of machining, a machining error dimension in regard to the norm dimension is stamped at the tip of the pinion, and the dimension under consideration of this machining error dimension and the norm dimension is called the standard dimension.

    2. A01CGQEE01

      Adjustment is made by changing the thickness of the drive pinion cage shim according to the difference between the measuring value and the tightening torque (conical distance).

      Standard dimension
      Norm dimension + machining error dimension

      Tech Tips

      When the machining error stamp at the tip of the pinion is 39, the machining error dimension is 0.39 mm (0.153 in.) (norm dimension + machining error dimension = standard dimension [27 mm (1.063 in.)+ 0.39 mm (0.153 in.)) = 27.39 mm (1.078 in.)]).

      Shim thickness
      Part No. Thickness
      41153-37090 0.30 mm (0.0118 in.)
      41153-37100 0.40 mm (0.0157 in.)
      41153-37110 0.45 mm (0.0177 in.)
      41153-37120 0.50 mm (0.0197 in.)
    3. A01CHYL

      Using a punch, stake the 2 portions of the pilot bearing lock nut.

  17. INSTALL DRIVE PINION SUB-ASSEMBLY


    1. A01CIRPE03

      Install the drive pinion sub-assembly and the drive pinion cage shim(s) to the rear differential carrier assembly.

      Note

      Be careful not to damage the O-ring when installing.

    2. A01CIVUE02

      Tighten the 6 bolts to the drive pinion sub-assembly with the rear differential carrier assembly.

      Torque:
      74 N*m  { 760 kgf*cm, 55 ft.*lbf }

  18. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01CGSZ

      Place the 2 bearing outer races on the 2 side bearings.

      Note

      Check that the left and right outer races are not interchanged.

    2. Using a chain block, install the rear differential case sub-assembly.

      Tech Tips

      Tilting the differential case, install the differential carrier.

    3. Install the 2 adjusting nuts on the carrier, make sure they are properly engaged.

      Tech Tips

      Making the 2 adjusting nuts horizontal to the side bearing, insert them from the top of the differential carrier.

    4. A01CHYZE01

      Align the matchmarks on the differential bearing cap and rear differential carrier. Temporarily install the side bearing caps with the 2 bolts.

      Tech Tips

      If the bearing cap does not tightly fit the carrier, the adjusting nuts may not be properly engaged. Reinstall the adjusting nuts if necessary.

  19. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A01CH2UE01

      Using SST, fully tighten the adjusting nut on the ring gear side. Loosen the nut by a 1/4 revolution.

      SST
      09504-00011

    2. Use the same procedures on the other side.

    3. A01CGOU

      Using a plastic hammer, lightly tap the top of the side bearing cap so that the bearing fits.

    4. A01CGVB

      Using a dial indicator, measure the backlash.

      Backlash:
      Reduction ratio Standard
      4.875 0.20 to 0.28 mm (0.0079 to 0.0110 in.)
      5.125 0.20 to 0.28 mm (0.0079 to 0.0110 in.)
      5.375 0.18 to 0.23 mm (0.0071 to 0.0091 in.)

      Tech Tips

      Perform the measurement at 3 or more positions around the circumference of the ring gear, and adjust the side bearing preload as necessary.

    5. The backlash should be adjusted by turning the left and right adjusting nuts by equal amounts. For example, if loosening the nut on the left side one notch, torque the nut on the right side one notch.

  20. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01CHI8

      Coat 3 or 4 teeth at 3 different positions on the ring gear with prussian blue.

    2. Turn the companion flange in both directions to inspect the ring gear for proper tooth contact.

      A01CGX7E13

      If the teeth are not properly contacting, use the table below to select a proper shim (drive pinion cage shim) for correction.

      Shim thickness:
      Part No. Thickness
      41153-37090 0.30 mm (0.0118 in.)
      41153-37100 0.40 mm (0.0157 in.)
      41153-37110 0.45 mm (0.0177 in.)
      41153-37120 0.50 mm (0.0197 in.)

      Tech Tips

      Use one or more shims for adjustment.

  21. INSPECT TOTAL PRELOAD


    1. A01CII0

      Using a deep socket wrench (41 mm) and torque wrench, measure the total preload.

    2. Calculate the side bearing preload by subtracting the drive pinion preload (starting torque after installing the oil seal) from the total preload. Check that the side bearing preload is within the specification.

      Side bearing preload (new bearing):
      Reduction ratio Standard
      4.875 0.31 to 0.40 N*m (3.2 to 4.1 kgf*cm, 2.7 to 3.5 in.*lbf)
      5.125 0.29 to 0.38 N*m (3.0 to 3.9 kgf*cm, 2.6 to 3.4 in.*lbf)
      5.375 0.27 to 0.36 N*m (2.8 to 3.7 kgf*cm, 2.4 to 3.2 in.*lbf)
      Side bearing preload (reused bearing):
      Reduction ratio Standard
      4.875 0.21 to 0.30 N*m (2.1 to 3.0 kgf*cm, 1.8 to 2.6 in.*lbf)
      5.125 0.20 to 0.28 N*m (2.0 to 2.9 kgf*cm, 1.7 to 2.5 in.*lbf)
      5.375 0.19 to 0.27 N*m (1.9 to 2.7 kgf*cm, 1.7 to 2.4 in.*lbf)

      Tech Tips


      • Total preload = Drive pinion preload + Side bearing preload

      • When replacing both or either side bearings, use the standard of the side bearing preload (new bearing).

    3. A01CH2UE01

      If the result is not as specified, then turn the left/right adjusting nuts using SST to adjust the preload.

      SST
      09504-00011

      Note

      When adjusting with the adjusting nuts, turn them by an equal amount so that the backlash will not be incorrect.

    4. A01CHEV

      Tighten the 2 bearing caps with the 4 bolts.

      Torque:
      210 N*m  { 2150 kgf*cm, 156 ft.*lbf }

    5. Recheck the total preload.

    6. A01CGVB

      Recheck the ring gear backlash.

      Backlash:
      Reduction ratio Standard
      4.875 0.20 to 0.28 mm (0.0079 to 0.0110 in.)
      5.125 0.20 to 0.28 mm (0.0079 to 0.0110 in.)
      5.375 0.18 to 0.23 mm (0.0071 to 0.0091 in.)

  22. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01CH36

      Install the 2 rear differential bearing adjusting nut locks on the 2 bearing caps.

      Torque:
      22 N*m  { 225 kgf*cm, 16 ft.*lbf }