DIFFERENTIAL CARRIER ASSEMBLY (for Ring Gear Size 8.0 inch) REASSEMBLY


  1. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY (for 2 Pinion Gear Type)

    A01KFN3

    1. Install the 2 side gear thrust washers to the side gears.

    2. A01KG2O

      Install the 2 side gears with the thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft.

      Tech Tips


      • Align the straight pin holes of the differential case and pinion shaft.

      • Apply hypoid gear oil to each sliding surface and rotating part.

    3. Secure the differential case in a vise using aluminum plates.

      Note

      Do not overtighten the vise, as the differential case may become deformed.

    4. A01KF90

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

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

      If the backlash is not within the specification, replace the side gear thrust washer with one of an appropriate thickness.

      Tech Tips

      Refer to the following table to select thrust washers which will ensure that the backlash is within the specification.

      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)
    5. A01KE9X

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

    6. A01KGR6

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

  2. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY (for 4 Pinion Gear Type)

    A01KFN3

    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.

      Tech Tips

      Apply hypoid gear oil to each sliding surface and rotating part.

    3. A01KEEM

      Secure the differential case in a vise using aluminum plates.

      Note

      Do not overtighten the vise, as the differential case may become deformed.

    4. 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.

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 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.

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 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) 1.0 (0.0394)
      1.1 (0.0433) 1.2 (0.0472)
      1.3 (0.0512) -
    9. A01KESPE01
      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:
      54 N*m  { 547 kgf*cm, 40 ft.*lbf }

  3. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY (for LSD)


    1. Install the 3 rear No. 1 differential side gear thrust washers and 3 clutch plates onto the differential side gear.

    2. A01KEDME01

      Using SST to press down the thrust washers and clutch plates with pressure of about 98 N (10 kgf, 22 lbf), measure dimension A as shown in the illustration.

      SST
      09649-17010
    3. A01KGQPE01

      Measure dimension B of the differential case, as shown in the illustration.

    4. Refer to the following table and select the proper thrust washer.

      Standard thrust washer thickness
      B - A - 16.175 mm (0.637 in.)
      Thrust Washer Thickness
      Thickness mm (in.) Mark
      1.86 (0.0732) B
      1.92 (0.0756) C
      1.98 (0.0780) D
      2.04 (0.0803) E
      2.10 (0.0827) F
      2.16 (0.0850) G
      2.22 (0.0874) H
      2.28 (0.0898) J
      2.34 (0.0921) K
      2.40 (0.0945) L
    5. A01KFLEE01
      Text in Illustration
      *1 Rear Differential Side Gear Thrust Washer
      *2 Clutch Plate
      *3 Rear No. 1 Differential Side Gear Thrust Washer
      *4 Rear Differential Side Gear

      Install the following parts to the differential case.

      Note

      Install the rear No. 1 differential side gear thrust washer and clutch plate alternatingly.

    6. A01KFK3E01
      Text in Illustration
      *1 Rear Differential Pinion
      *2 Spring Retainer
      *3 Rear Differential Pinion Thrust Washer

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

      Tech Tips

      Apply hypoid gear oil LSD to each sliding surface and rotating part.

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

    8. Install the pinion gear and spider onto the differential case RH.

      Tech Tips

      Install the spider to the differential case RH tightly and do not move the spring retainer.

    9. A01KF4C

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

      Standard backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

      Tech Tips


      • Measure the backlash at all 4 locations.

      • Measure the backlash at the LH and RH cases.

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

    10. Reinstall the spider and spring retainer RH onto the differential case RH.

      Tech Tips

      Install the spider to the differential case RH tightly and do not move the spring retainer.

    11. Install the compression spring and spring retainer LH.

    12. A01KFBO

      Install the side gear, thrust washers and clutch plates.

    13. A01KESPE01
      Text in Illustration
      *a Matchmark

      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.

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

      Torque:
      54 N*m  { 547 kgf*cm, 40 ft.*lbf }

      Note

      Tighten the bolts gradually, always skipping to a diagonally opposite bolt.

  4. INSTALL DIFFERENTIAL RING GEAR


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

    2. A01KHOLE15
      Text in Illustration
      *a Boiling Water

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

      CAUTION:

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

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

    4. A01KIJVE01
      Text in Illustration
      *a Matchmark

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

    5. Temporarily install 5 new ring gear plates and 10 bolts.

    6. After the ring gear cools down enough, torque the 10 bolts uniformly at a time.

      Torque:
      87 N*m  { 891 kgf*cm, 64 ft.*lbf }

      Tech Tips

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

    7. A01KF0H

      Using a chisel and a hammer, stake the 5 ring gear plates.

      Note

      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.

  5. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01KH1RE01

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

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

  6. INSPECT DIFFERENTIAL RING GEAR RUNOUT


    1. Install the differential case on the differential 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:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }
    3. A01KI0H

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

      Maximum runout
      0.07 mm (0.00276 in.)

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

  7. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01KHIKE01

      Using SST and a press, install the rear drive pinion front tapered roller bearing outer race to the differential carrier.

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

  8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01KHDJE01

      Using SST and a press, install the rear drive pinion rear tapered roller bearing outer race to the differential carrier.

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

  9. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. Install the plate washer on the drive pinion.

    2. A01KGIGE01

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

      SST
      09506-30012

  10. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01KEHQ

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

      Tech Tips

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

    2. A01KEN6E01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the drive pinion companion flange.

      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.

    3. A01KEWSE01

      Using SST to hold the flange, tighten the nut.

      SST
      09330-00021
      Torque:
      370 N*m  { 3772 kgf*cm, 272 ft.*lbf, or less }

      Note


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

      • Apply hypoid gear oil LSD to drive pinion thread and nut seat face.

    4. A01KFSW

      Using a torque wrench, measure the preload.

      Standard preload (at Starting)
      Bearing Preload
      New 0.95 to 1.54 N*m (10 to 15 kgf*cm, 9 to 13 in.*lbf)
      Reused 0.46 to 0.75 N*m (5 to 7 kgf*cm, 5 to 6 in.*lbf)

  11. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


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

      Note

      Make sure the right and left races are not interchanged.

    2. A01KESD

      Install the differential case on the differential carrier.

  12. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT


    1. A01KEBW

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

    2. A01KIIQE01
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the cap and differential carrier.

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

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }

      Tech Tips

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

  13. ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION


    1. Tighten 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
    2. A01KGTZE01

      Using SST, tighten the adjusting nut on the ring gear side until the ring has a backlash of approximately 0.18 mm (0.007 in.).

      SST
      09504-00011
    3. A01KICQE01

      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.

      SST
      09504-00011

    4. Using SST, tighten the adjusting nut 1 to 1.5 notches from the 0 preload position.

      SST
      09504-00011
    5. A01KH9ZE01

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

      SST
      09504-00011
      Standard backlash
      0.13 to 0.18 mm (0.00512 to 0.00708 in.)

      Note

      Measure at 3 or more positions around the circumference of the ring gear.

      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.

    6. Tighten the 4 bearing cap bolts.

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }

  14. INSPECT TOTAL PRELOAD

    A01KFSW

    1. Using a torque wrench, measure the total preload with the teeth of the drive pinion and ring gear in contact.

      Total preload
      Drive pinion preload + 0.39 to 0.59 N*m (4 to 6 kgf*cm, 3 to 5 in.*lbf)

      If the total preload is not within the specified range, adjust the total preload or repair as necessary.

      Note

      Record the ring gear preload.

  15. 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 Prussian blue.

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

    3. Inspect the tooth contact pattern.

      A01KG3QE05
      Text in Illustration
      *a Proper Contact *b Heel Contact
      *c Face Contact *d Select an adjusting washer that will bring the drive pinion closer to the ring gear.
      *e Toe Contact *f Flank Contact
      *g Select an adjusting washer that will shift the drive pinion away from the ring gear - -
    4. A01KHHCE01
      Text in Illustration
      *1 Plate Washer

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

      Plate washer thickness
      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)

  16. REMOVE REAR DRIVE PINION NUT

    A01KHQDE01

    1. Using SST and a socket wrench 30 mm, hold the rear drive pinion companion flange sub-assembly and remove the rear drive pinion nut.

      SST
      09330-00021

  17. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    A01KEP8E01
    Text in Illustration
    *a Turn
    *b Hold

    1. Using SST, remove the rear drive pinion companion flange sub-assembly.

      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.

  18. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. Remove the rear differential drive pinion oil slinger.

  19. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01KFWGE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the rear drive pinion front tapered roller bearing from the drive pinion.

      SST
      09556-22010

      Note

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

  20. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01KGQ6

      Install a new drive pinion bearing spacer to the drive pinion.

      Note

      Be sure to face the larger inner diameter side as shown in the illustration.

  21. INSTALL DIFFERENTIAL OIL STORAGE RING


    1. Using a brass bar and a hammer, install a new differential oil storage ring onto the differential carrier.

  22. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. Install the rear drive pinion front tapered roller bearing.

  23. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. Install the rear differential drive oil slinger.

  24. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01KI8NE01

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

      SST
      09554-30011
      Oil seal drive in depth
      0.55 to 1.45 mm (0.0217 to 0.0570 in.)

    2. Apply MP grease to the oil seal lip.

  25. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR


    1. A01KFU4E01
      Text in Illustration
      *a Plate

      Using a press and a plate, install a new rear differential dust deflector.

      Note

      Be careful not to damage the dust deflector.

  26. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01KIDNE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the drive pinion companion flange.

      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. Apply hypoid gear oil LSD to drive pinion thread and a new drive pinion nut seat face.

    3. A01KEWSE01

      Using SST to hold the flange, install the drive pinion nut.

      SST
      09330-00021
      Torque:
      370 N*m  { 3772 kgf*cm, 272 ft.*lbf, or less }

  27. INSPECT DRIVE PINION PRELOAD


    1. A01KFSW

      Using a torque wrench, measure the preload.

      Standard preload (at Starting)
      Bearing Preload
      New 1.05 to 1.64 N*m (10 to 16 kgf*cm, 10 to 14 in.*lbf)
      Reused 0.56 to 0.85 N*m (6 to 9 kgf*cm, 5 to 7 in.*lbf)

      Note


      • If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 10° to adjust it into the specified range.

      • If the preload is less than the specified minimum value even when the tightening torque of the drive pinion nut is greater than the specified maximum value, loosen the nut and check that the threads of the drive pinion nut and drive pinion are not stripped.

      • If the threads are not stripped, replace the bearing spacer. Apply hypoid gear oil LSD to the threads of the drive pinion and repeat the procedure.

  28. INSPECT TOTAL PRELOAD


    1. A01KFSW

      Using a torque wrench, measure the total preload with the teeth of the drive pinion and ring gear in contact.

      Total preload
      Bearing Preload
      New Ring gear preload + 1.05 to 1.64 N*m (10 to 16 kgf*cm, 10 to 14 in.*lbf)
      Reused Ring gear preload + 0.56 to 0.85 N*m (6 to 9 kgf*cm, 5 to 7 in.*lbf)

      If necessary, disassemble and inspect the differential.

  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 as specified, adjust the side bearing preload or perform repairs as necessary.

      Note

      Measure at 3 or more positions around the circumference of the ring gear.

  30. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE


    1. A01KG6FE01
      Text in Illustration
      *a Vertical Runout
      *b Horizontal Runout

      Using a dial indicator, measure the vertical and horizontal runout of the companion flange.

      Maximum Runout
      Runout Specified Condition
      Vertical runout 0.10 mm (0.00394 in.)
      Horizontal runout 0.10 mm (0.00394 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 adjusting nut locks on the bearing caps with the 2 bolts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    2. After tightening belts, bend the rear differential bearing adjusting nut locks.