DIFFERENTIAL CARRIER ASSEMBLY (for Ring Gear Size 10.5 inch) REASSEMBLY


  1. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR


    1. A01KGHNE08
      Text in Illustration
      *1 Plate

      Using a press, install the rear differential dust deflector.

      SST
      09631-12090

      Note

      Be careful not to damage the dust deflector.

  2. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01KFXJ

      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
      0.02 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 pinion toward the case.

      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. A01KHJVE01
      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. 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. A01KIGQE01
      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:
      161.8 N*m  { 1650 kgf*cm, 119 ft.*lbf }

      Tech Tips

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

    8. A01KIAE

      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


    1. A01KHD7E01

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

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

  5. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

    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:
      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


    1. A01KG4BE01

      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


    1. A01KI13E01

      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


    1. A01KI8IE02

      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


    1. A01KG4J

      Install the drive pinion, spacer, 2 shims, front tapered roller bearing and the oil slinger.

      Tech Tips


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

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

    2. A01KEFBE10

      Using SST, install the drive pinion companion flange.

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

      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. A01KGGP

      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 axial 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.

      Torque:
      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 REAR DIFFERENTIAL CASE ASSEMBLY


    1. A01KEVG

      Place the 2 bearing outer races on their respective bearings.

      Tech Tips

      Make sure the right and left races are not interchanged.

    2. A01KG2I

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

  11. 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:
      196 N*m  { 1997 kgf*cm, 145 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. A01KF1K

      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 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. A01KF12E01

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

      Backlash
      0.15 to 0.20 mm (0.0059 to 0.0079 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. A01KFUPE01
      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.

      Torque:
      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


    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. 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.

      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


    1. A01KEOKE01

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

      SST
      09223-78010
      Oil seal drive in depth
      0.45 mm (0.0177 in.)

    2. Coat MP grease to the oil seal lip.

  15. 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, 09956-03040 )

    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:
      275 to 333 N*m  { 2804 to 3396 kgf*cm, 203 to 246 ft.*lbf }

  16. 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
      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 }

      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.

  17. INSPECT TOTAL PRELOAD


    1. Using a torque wrench, measure the preload.

      Torque:
      Total preload (at starting)
      Drive pinion preload plus
      0.2 to 0.39 N*m  { 2 to 4 kgf*cm, 1.8 to 3.5 in.*lbf }

  18. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION

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

  20. INSTALL REAR DRIVE PINION NUT


    1. A01KF7J

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

  21. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01KI7ZE01
      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, 96 ft.*lbf }

    2. After tightening belts, bend the nut locks.