DIFFERENTIAL CARRIER ASSEMBLY (for Ring Gear Size 8.0 inch) 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
      09636-20010

  2. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY (2 PINION DIFFERENTIAL)


    1. A01KGQZ

      Install the 2 thrust washers on the 2 side gears.

    2. A01KG2O

      Install the 2 side gears, 2 differential pinions, 2 differential pinion thrust washers and differential pinion shaft in the differential case.

      Tech Tips

      Align the holes of the differential case and differential pinion shaft.

    3. A01KF90

      Measure the side gear backlash while holding 1 pinion gear toward the case.

      Backlash
      0.05 to 0.20 mm (0.002 to 0.008 in.)

      If the backlash is not within the specification, install a thrust washer of the different thickness.

      Thrust washer thickness
      Thickness mm (in.)
      1.57 to 1.63 (0.0618 to 0.0642)
      1.67 to 1.73 (0.0657 to 0.0681)
      1.77 to 1.83 (0.0697 to 0.0720)
    4. A01KFWK

      Using a pin punch (5 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft.

    5. Using a chisel and a hammer, stake the outside of the differential case pin hole.

  3. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY (4 PINION DIFFERENTIAL)


    1. A01KFN3

      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. A01KEEM

      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 pinion toward the case.

      Backlash
      0.05 to 0.20 mm (0.002 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 LH side backlash while holding pinion toward the case.

      Backlash
      0.05 to 0.20 mm (0.002 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.)
      0.9 (0.0354) 1.2 (0.0472)
      1.0 (0.0394) 1.3 (0.0512)
      1.1 (0.0433) -
    9. A01KHDBE07
      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 8 bolts.

      Torque:
      47 N*m  { 480 kgf*cm, 35 ft.*lbf }

  4. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY (W/LSD DIFFERENTIAL)

    Tech Tips


    • Using a shop rag, clean off any foreign matter from the parts.

    • Apply all of the sliding and rotating surfaces with LSD oil.


    1. A01KFLEE01
      Text in Illustration
      *1 Rear differential side gear thrust washer
      *2 Rear differential side gear thrust washer No. 1
      *3 Clutch plate
      *4 Differential side gear

      Install the there parts to the differential case.

    2. A01KIAR

      Install the 4 pinion gears and thrust washers to the spider.

    3. Align the spring RH retainer holes with the spider knock pins and install the RH retainer.

    4. Install the pinion gear and spider to the differential RH case.

      Tech Tips

      Install the spider to the RH case tightly and don't move the spring retainer.

    5. A01KF4C

      Using a dial indicator, measure the side gear backlash while hold the side gear and spider.

      Backlash
      0.05 to 0.20 mm (0.0020 to 0.0079 in.)

      Tech Tips


      • Measure at all 4 locations.

      • Measure the backlash at the LH case and at the RH case.

      If the backlash is not within the specification, install a adjusting shim of a different thickness.

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      B 1.86 (0.0732) G 2.16 (0.0850)
      C 1.92 (0.0756) H 2.22 (0.0874)
      D 1.98 (0.0780) J 2.28 (0.0898)
      E 2.04 (0.0803) K 2.34 (0.0921)
      F 2.10 (0.0827) L 2.40 (0.0945)

    6. Reinstall the spider and spring RH retainer to the differential RH case.

      Tech Tips

      Install the spider to the RH case tightly and don't move the spring retainer.

    7. Install the compression spring and spring LH retainer.

    8. A01KFBO

      Install the side gear, thrust washers and clutch plates.

    9. Align the matchmarks and assemble the RH and LH cases.

      Tech Tips

      Be careful not to drop the side gear and check the pinion and side gear alignment.

    10. Tighten the 8 bolts uniformly, a little at a time.

      Torque:
      47 N*m  { 480 kgf*cm, 35 ft.*lbf }

  5. INSTALL DIFFERENTIAL RING GEAR


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

    2. A01KHOLE10
      Text in Illustration
      *a Boiling Water

      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. A01KG59E09
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the ring gear and differential case.

    6. Temporarily install 5 new lock plates and 10 bolts.

    7. After the ring gear cools down enough, torque the 8 bolts uniformly at a time.

      Torque:
      97 N*m  { 985 kgf*cm, 71 ft.*lbf }

      Tech Tips

      Tighten the bolts in diagonal order little by little over several times.

    8. A01KF0H

      Using a chisel and a hammer, stake the 5 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.

  6. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01KGYXE05

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

      SST
      09950-60010   ( 09951-00430, 09951-00480, 09951-00470, 09951-00550 )
      09950-70010   ( 09951-07150 )

  7. INSPECT DIFFERENTIAL RING GEAR RUNOUT

    A01KI0H

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

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

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

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

      Maximum runout
      0.07 mm (0.0028 in.)

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

  8. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01KGDHE04

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

      SST
      09316-60011   ( 09316-00011, 09316-00021 )

  9. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01KIAAE01

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

      SST
      09316-60011   ( 09316-00011, 09316-00041, 09316-00031 )

  10. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01KI8IE02

      Install the plate washer on the drive pinion.

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

      SST
      09506-30012

  11. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01KEHQ

      Install the drive pinion, rear drive pinion tapered roller bearing and rear differential drive oil slinger.

      Tech Tips

      Assemble the spacer and oil seal after adjusting the gear contact pattern.

    2. A01KEFBE10

      Using SST, install the drive pinion companion flange.

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

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

    4. A01KI8WE01

      Using SST to hold the flange, torque the nut.

      Torque:
      343 N*m  { 3500 kgf*cm, 253 ft.*lbf }

      Note


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

      • Apply hypoid gear oil LSD of the nut.

    5. A01KFSW

      Using a torque wrench, measure the preload.

      Torque:
      Preload (at starting)
      New bearing
      0.98 to 1.57 N*m  { 10 to 16 kgf*cm, 8.7 to 14 in.*lbf }
      Reused bearing
      0.49 to 0.78 N*m  { 5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf }

  12. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01KESD

      Place the 2 bearing outer races on their respective bearings.

      Tech Tips

      Make sure the right and left races are not interchanged.

  13. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT


    1. A01KEBW

      Install the rear differential bearing adjusting nuts on the carrier, making sure the nuts are threaded properly.

  14. 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:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Tech Tips

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

    3. A01KG0O

      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. While turning the ring gear, use the 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. A01KF7TE01

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

      Backlash
      0.13 to 0.18 mm (0.0051 to 0.0071 in.)
      SST
      09504-00011

      Tech Tips

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

    8. A01KG3ME05
      Text in Illustration
      *a Matchmark

      Torque the bearing cap bolts.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

  15. INSPECT TOTAL PRELOAD


    1. A01KFSW

      Using a torque wrench, measure the drive pinion preload.

      Torque:
      Total preload (at starting)
      Drive pinion preload plus
      0.39 to 0.59 N*m  { 4.0 to 6.0 kgf*cm, 3.5 to 5.2 in.*lbf }

  16. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01KGBK

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

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

    3. Inspect the tooth contact pattern.

      A01KIPPE18
      Text in Illustration
      *a Proper Contact *b Heel Contact
      *c Face Contact *d Toe Contact
      *e Flank Contact *f Select an adjusting washer that will bring the drive pinion closer to the ring gear.
      *g Select an adjusting washer that will shift the drive pinion away from the ring gear. - -
    4. A01KG27E06
      Text in Illustration
      *1 Plate Washer

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

      Thickness mm (in.) Thickness mm (in.)
      1.70 (0.0669) 2.03 (0.0799)
      1.73 (0.0681) 2.06 (0.0811)
      1.76 (0.0693) 2.09 (0.0823)
      1.79 (0.0705) 2.12 (0.0835)
      1.82 (0.0717) 2.15 (0.0846)
      1.85 (0.0728) 2.18 (0.0858)
      1.88 (0.0740) 2.21 (0.0870)
      1.91 (0.0752) 2.24 (0.0882)
      1.94 (0.0764) 2.27 (0.0894)
      1.97 (0.0776) 2.30 (0.0906)
      2.00 (0.0787) 2.33 (0.0917)

  17. REMOVE REAR DRIVE PINION NUT

    SST
    09330-00021

  18. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR

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

  19. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  20. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    SST
    09556-22010

  21. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

  22. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

  23. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

  24. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  25. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01KEOKE01

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

      SST
      09554-30011
      Oil seal drive in depth
      0.7 to 1.3 mm (0.028 to 0.051 in.)

    2. Coat MP grease to the oil seal lip.

  26. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR


    1. A01KEFBE10

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

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

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

    3. A01KHDWE01

      Using SST to hold the flange, torque the nut.

      SST
      09330-00021
      Torque:
      196 to 343 N*m  { 2000 to 3500 kgf*cm, 145 to 254 ft.*lbf }

  27. INSPECT DRIVE PINION PRELOAD


    1. A01KHK6

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

      Torque:
      Preload (at starting)
      New bearing
      0.98 to 1.57 N*m  { 10 to 18 kgf*cm, 8.7 to 14 in.*lbf }
      Reused bearing
      0.49 to 0.78 N*m  { 5 to 8 kgf*cm, 4.3 to 7.0 in.*lbf }

      Tech Tips


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

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

      Torque:
      343 N*m  { 3500 kgf*cm, 235 ft.*lbf, or less }

      If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure. Do not loosen the pinion nut to reduce the preload.

  28. INSPECT TOTAL PRELOAD


    1. A01KHK6

      Using a torque wrench, measure the preload.

      Torque:
      Total preload (at starting)
      Drive pinion preload plus
      0.39 to 0.59 N*m  { 4.0 to 6.0 kgf*cm, 3.5 to 5.2 in.*lbf }

  29. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01KGJI

      Using a dial indicator, check the backlash of the ring gear.

      Backlash
      0.13 to 0.18 mm (0.0051 to 0.0071 in.)

      If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

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


    1. A01KF1CE03

      Using a dial indicator, measure the runout of the companion flange vertically and horizontally.

      Maximum runout
      0.1 mm (0.0039 in.)

  31. INSTALL REAR DRIVE PINION NUT


    1. A01KGSZ

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

  32. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01KH2V

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

      Torque:
      13 N*m  { 133 kgf*cm, 96 ft.*lbf }

    2. After tightening belts, bend the nut locks.