DIFFERENTIAL CARRIER ASSEMBLY (for 4 Pinion Gear Type) REASSEMBLY


  1. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR


    1. A01KGHNE08
      Text in Illustration
      *1 Plate

      Using a press, install the rear differential dust deflector.

      Note

      Be careful not to damage the dust deflector.

      SST
      09631-12090

  2. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY

    A01KG8C

    1. Install the rear differential side gear thrust washer to the rear differential side gear.

    2. Install the rear differential pinion thrust washer and rear differential pinion to the rear differential spider.

    3. Fix the differential case RH.

    4. A01KGU6

      Install the rear differential side gear and rear differential spider to the differential case RH.

    5. A01KFVP

      Using a dial indicator, measure the differential case RH side backlash while holding the pinion toward the case.

      Standard backlash
      0.02 to 0.20 mm (0.0008 to 0.008 in.)

    6. Remove the rear differential spider from the differential case RH.

    7. A01KHTR

      Install the rear differential side gear and rear differential spider to the differential case LH.

    8. Using a dial indicator, measure the differential case RH side backlash while holding the pinion toward the case.

      Standard backlash
      0.02 to 0.20 mm (0.0008 to 0.008 in.)

      If the backlash is not within the specification, install the 2 side gear thrust washers with different thickness.

      Thrust washer thickness
      Thickness mm (in.) Thickness mm (in.)
      1.53 to 1.57 (0.0602 to 0.0618) 1.83 to 1.87 (0.0720 to 0.0736)
      1.58 to 1.62 (0.0622 to 0.0638) 1.88 to 1.92 (0.0740 to 0.0756)
      1.63 to 1.67 (0.0641 to 0.0657) 1.93 to 1.97 (0.0760 to 0.0776)
      1.68 to 1.72 (0.0661 to 0.0677) 1.98 to 2.02 (0.0780 to 0.0795)
      1.73 to 1.77 (0.0681 to 0.0697) 2.03 to 2.07(0.0800 to 0.0815)
      1.78 to 1.82 (0.0700 to 0.0717) 2.08 to 2.12 (0.0819 to 0.0835)
    9. A01KIHLE05
      Text in Illustration
      *a Matchmark

      Align the matchmarks and assemble the RH and LH cases.

    10. Using a plastic hammer, install the differential case.

    11. Install the 12 bolts.

      Torque:
      78.5 N*m  { 800 kgf*cm, 58 ft.*lbf }

  3. INSTALL DIFFERENTIAL RING GEAR


    1. A01KHOLE10
      Text in Illustration
      *a Boiling Water

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

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

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

    4. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

    5. A01KIOXE03
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the ring gear and differential case.

    6. Temporarily install 6 new lock plates and 12 bolts.

    7. After the ring gear cools down enough, torque the 12 bolts uniformly at a time.

      Torque:
      162 N*m  { 1652 kgf*cm, 119 ft.*lbf }
    8. A01KGUEE01

      Using a chisel and a hammer, stake the 6 lock plates.

      Tech Tips

      Stake one claw so that it is flush with the flat surface of the bolt.

      For the claw contacting the protruding portion of the bolt, stake only the half on the tightening side.

  4. INSTALL REAR DIFFERENTIAL CASE BEARING

    A01KEIOE01

    1. Using SST and a press, install the bearing on the differential case.

      SST
      09316-20011
      09950-60010   ( 09951-00500 )

  5. INSPECT DIFFERENTIAL RING GEAR RUNOUT

    A01KI0H

    1. Install the differential case on the carrier, and install the 2 adjusting nuts so that there is no play in the bearing.

    2. Install the 2 bearing caps with the 4 bolts.

      Torque:
      196 N*m  { 1997 kgf*cm, 145 ft.*lbf }

    3. Using a dial indicator, measure the runout of the ring gear.

      Maximum runout
      0.01 mm (0.00039 in.)

    4. Remove the 2 bearing caps, 2 adjusting nuts and differential case.

  6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    A01KF9NE01

    1. Using SST and a press, install the front bearing (outer race) to the carrier.

      SST
      09950-60020   ( 09951-00780 )
      09950-70010   ( 09951-07150 )

  7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    A01KERLE02

    1. Using SST and a press, install the rear bearing (outer race) to the carrier.

      SST
      09950-60020   ( 09951-01030 )
      09950-70010   ( 09951-07150 )

  8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    A01KI8IE02

    1. Install the removed plate washer on the drive pinion.

    2. Using SST and a press, install the rear bearing onto the drive pinion.

      SST
      09506-35010

  9. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

    A01KG4J

    1. Install the drive pinion, spacer, differential oil storage ring, 2 shims, front bearing and oil slinger.

      Tech Tips


      • When replace the drive pinion bearing, install the thickest shim A and B.


      • Assemble and install the oil seal after adjusting the total preload.

    2. A01KEFBE03

      Using SST, install the drive pinion companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040 )
      09330-00021   ( 09330-00030 )
      09330-00021

    3. Coat the threads of the nut with hypoid oil LSD.

    4. A01KI8WE02

      Using SST to hold the flange, torque the nut.

      SST
      09330-00021
      Torque:
      275 to 333 N*m  { 2804 to 3396 kgf*cm, 203 to 246 ft.*lbf }

      Note

      As there is no spacer, torque a little at a time, being careful not to overtighten it.

    5. Using a dial indicator, measure and note the drive pinion axial play.

    6. Calculate the value "T".

      T = 4.89 mm (0.1925 in.) - (drive pinion axal play)

      Select shims A and B so that the sum of the 2 shims is closest to value "T"

      Shim A thickness mm (in.)

      at intervals of 0.1 (0.0039)

      Shim B thickness mm (in.)

      at intervals of 0.01 (0.0004)
      1.90 (0.0748) 2.50 (0.0984) 1.80 (0.0709) 1.85 (0.0728)
      2.00 (0.0787) 2.60 (0.1024) 1.81 (0.0713) 1.86 (0.0732)
      2.10 (0.0827) 2.70 (0.1063) 1.82 (0.0717) 1.87 (0.0736)
      2.20 (0.0866) 2.80 (0.1102) 1.83 (0.0720) 1.88 (0.0740)
      2.30 (0.0906) 2.90 (0.1142) 1.84 (0.0724) 1.89 (0.0744)
      2.40 (0.0945) 3.00 (0.1181) -
    7. A01KFSW

      Using a torque wrench, measure the preload.

      Preload (at starting):

      New bearing
      2.00 to 5.39 N*m (20 to 55 kgf*cm, 18 to 48 in.*lbf)
      Reused bearing
      1.00 to 2.76 N*m (10 to 28 kgf*cm, 8.9 to 24 in.*lbf)

  10. INSTALL DIFFERENTIAL CASE ASSEMBLY

    A01KEVG

    1. Place the 2 bearing outer races on their respective bearings.

      Tech Tips

      Make sure the right and left races are not interchanged.

    2. A01KGUU

      Install the 2 adjusting nuts on the carrier, making sure the nuts are threaded properly.

  11. INSPECT AND ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION


    1. A01KG3ME05
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the cap and carrier.

    2. Install the right and left bearing caps with the 4 bolts.

      Torque:
      205 N*m  { 2091 kgf*cm, 151 ft.*lbf }

      • Tech Tips


        • If the bearing cap does not fit tightly on the carrier, the adjusting nuts are not threaded properly.


        • Reinstall the adjusting nuts if necessary.

    3. A01KESO

      Torque the 4 bearing cap bolts to the specified torque, then loosen them to the point where the adjusting nuts can be turned by SST.

      SST
      09504-00011
    4. A01KH35E01

      Using the SST, torque the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008 in.).

      SST
      09504-00011
    5. A01KILVE01

      While turning the ring gear, use SST to fully tighten the adjusting nut on the drive pinion side. After the bearings as settled, loosen the adjusting nut on the drive pinion side.

    6. Using SST, torque the adjusting nut 1 to 1.5 notches from the 0 preload position.

      SST
      09504-00011
    7. A01KF12E01

      Using a dial indicator, adjust the ring gear backlash until it is within the specification.

      Standard backlash
      0.15 to 0.20 mm (0.0059 to 0.0079 in.)

      Tech Tips


      • The backlash is adjusted by turning the left and right adjusting nuts an equal amount. For example, loosen the nut on the right side one notch and loosen the nut on the left side one notch.


      • Perform the measurement at 3 or more positions around the circumference of the ring gear.

    8. A01KFZZE02
      Text in Illustration
      *a Matchmark

      Torque the bearing cap bolts.

      Torque:
      196 N*m  { 1997 kgf*cm, 145 ft.*lbf }

  12. INSPECT TOTAL PRELOAD


    1. A01KFSW

      Using a torque wrench, measure the drive pinion preload.

      Total Preload (at starting)
      Drive pinion preload plus 0.2 to 0.39 N*m (2.0 to 3.0 kgf*cm, 1.8 to 3.5 in.*lbf)

  13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

    A01KGBKE01

    1. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.

    2. Hold the companion flange firmly in place and rotate the ring gear in both directions.

    3. Inspect the tooth contact pattern.

      A01KFIQE05
      Text in Illustration
      *a Proper Contact *b Driver Side
      *c Toe Contact *d Face Contact
      *e Select an adjusting washer that will bring the drive pinion closer to the ring gear. *f Heel Contact
      *g Flank Contact *h Select an adjusting washer that will shift the drive pinion away from the ring gear.
      *i Coast Side *j Heel Contact
      *k Flank Contact *l Select an adjusting washer that will bring the drive pinion closer to the ring gear.
      *m Toe Contact *n Face Contact
      *o Select an adjusting washer that will shift the drive pinion away from the ring gear. - -

      • A01KEEAE02
        Text in Illustration
        *1 Plate Washer

        If the teeth are not contacting properly, use the following chart to select a proper washer.

        Standard plate washer thickness
        Thickness mm (in.) Thickness mm (in.)
        1.05 (0.0413) 1.325 (0.0522)
        1.075 (0.0423) 1.35 (0.0531)
        1.10 (0.0433) 1.375 (0.0541)
        1.125 (0.0443) 1.40 (0.0551)
        1.15 (0.0453) 1.425 (0.0561)
        1.175 (0.0463) 1.45 (0.0571)
        1.20 (0.0472) 1.475 (0.0581)
        1.225 (0.0482) 1.50 (0.0591)
        1.25 (0.0492) 1.525 (0.0600)
        1.275 (0.0502) 1.55 (0.0610)
        1.30 (0.0512) -

  14. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

    A01KEOKE01

    1. Using SST and a hammer, install a new rear differential carrier oil seal.

      SST
      09223-78010
      Standard oil seal depth
      0.45 mm (0.0177 in.)

    2. Apply MP grease to a new oil seal.

  15. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01KEFBE17
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the companion flange on the drive pinion.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040 )

      Note

      Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

    2. Coat the threads of a new nut with hypoid gear oil LSD.

    3. A01KHDWE05

      Using SST to hold the flange, torque the nut.

      SST
      09330-00021   ( 09330-00030 )
      Torque:
      275 to 333 N*m  { 2804 to 3,770 kgf*cm, 203 to 246 ft.*lbf, or less }

  16. INSPECT DRIVE PINION PRELOAD

    A01KHK6E01

    1. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

      Standard drive pinion preload (at start of torque)
      Bearing Preload
      New bearing 2.00 to 5.39 N*m (20 to 55 kgf*cm, 18 to 48 in.*lbf)
      Reused bearing 1.00 to 2.76 N*m (10 to 28 kgf*cm, 8.9 to 24 in.*lbf)

      • If the preload is greater than the maximum, replace the bearing spacer.


      • If the preload is less than the minimum, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached.

  17. INSPECT TOTAL PRELOAD


    1. Using a torque wrench, measure the preload.

      Total Preload (at starting)
      Drive pinion preload plus 0.2 to 0.39 N*m (2.0 to 4.0 kgf*cm, 1.8 to 3.5 in.*lbf)

  18. INSPECT DIFFERENTIAL RING GEAR BACKLASH

  19. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

  20. STAKE DRIVE PINION NUT

    A01KF7J

    1. Using a chisel and a hammer, stake the drive pinion nut.

  21. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01KEH3E02
      Text in Illustration
      *1 No. 1 Rear Differential Bearing Adjust Lock
      *2 No. 2 Rear Differential Bearing Adjust Lock

      Install 2 new rear differential bearing adjust lock on the bearing caps.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    2. After tightening bolts, bend the nut locks.