REAR DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY


  1. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR


    1. A01BBRIE01

      Using steel plate and a press, install a new dust deflector.

      Note


      • Slowly press in the dust deflector.

      • If any burrs remain after pressing in the deflector, remove them.

  2. INSTALL REAR DIFFERENTIAL PINION SHAFT PIN


    1. A01BGF9

      Install the 2 thrust No.1 washers to the 2 side gears.

      Note


      • Make sure that there is no dirt or foreign matter on the thrust washer, side gear, etc. before installing them.

      • If replacing either the side gear or pinion, replace them as a set.

      • Apply hypoid gear oil API GL-5 to all sliding and rotating parts.

    2. A01BG46

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

      Note

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

    3. Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    4. A01BGIN

      Using a dial indicator, measure the side gear backlash while holding 1 pinion gear toward the differential case.

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

      If the backlash is not within the specified range, install the 2 side gear thrust No.1 washers of different thicknesses.

      Tech Tips

      Refer to the following table to select the 2 side gear thrust No.1 washers.

      Thrust No.1 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. A01BES0

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

    6. A01BE01

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

  3. INSTALL DIFFERENTIAL RING GEAR


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

    2. Clean the differential ring gear set bolt hole.

    3. A01BHG1E01

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

      CAUTION:

      Use thick gloves to protect 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 between aluminum plates.

      Note

      Do not overtighten the vise.

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

    7. A01BBQSE01

      Align the matchmarks on the ring gear and differential case.

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

    9. After the ring gear cools down, tighten the 10 bolts uniformly.

      Torque:
      97 N*m  { 985 kgf*cm, 72 ft.*lbf }

      Tech Tips

      Tighten the bolts in diagonal order little by little in several steps.

    10. A01BCEU

      Using a chisel and a hammer, stake the 5 lock plates.


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

      2. Stake the other claw against the surface of the bolt head to act as a stopper if the bolt starts to loosen.

  4. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01BI6AE01

      Using SST and a press, install the case bearing inner races LH and RH to the differential case.

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

      Note


      • Do not apply hypoid gear oil to a new bearing.

      • Do not deform the bearing cage.

      • Set the SST to the center of the differential case.

      • If the bearing is replaced, replace it and the outer race as a set.

  5. INSPECT DIFFERENTIAL RING GEAR RUNOUT


    1. Install the case bearing outer races LH and RH to the case bearing inner races LH and RH respectively.

      Note

      Be sure to install the bearing outer races in each correct position.

    2. A01BGG9

      Install the differential case to the differential carrier.

    3. A01BGPH

      Install the 2 bearing adjusting nuts.

    4. A01BBPGE01

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

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }
    5. A01BARJ

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

      Maximum runout
      0.07 mm (0.0028 in.)

      If the runout is greater than the maximum, replace the drive pinion, ring gear and differential case.

    6. Remove the right and left bearing caps and differential case.

  6. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01BCHTE01

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

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

  7. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01BGJGE01

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

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

  8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. Install the drive pinion plate washer to the drive pinion.

    2. A01BE45E01

      Using SST and a press, install the inner race of the rear drive pinion rear tapered roller bearing to the drive pinion.

      SST
      09506-30012

  9. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01BFHF

      Install the drive pinion and the inner race of the rear drive pinion front tapered roller bearing and oil slinger to the differential carrier.

    2. A01BB4OE01

      Using SST, install the companion flange.

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

      Note

      Apply grease to the threads and tip of the SST center bolt before use.

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

    4. A01BBXEE01

      Using SST, hold the flange.

      SST
      09330-00021

    5. Using a socket wrench (30 mm) and torque wrench, gradually tighten the drive pinion nut within the adjustment range of the differential drive pinion preload.

      Torque
      370 N*m (3,770 kgf*cm, 273 ft.*lbf) or less

      Note

      As there is no bearing spacer, tighten the nut a little at a time and do not overtighten.

    6. Turn the bearing clockwise and counterclockwise several times to stabilize it.

    7. A01BFEV

      Using a socket wrench (30 mm) and torque wrench, measure the preload.

      Drive pinion preload (at starting)
      New bearing
      1.05 to 1.64 N*m (11.0 to 17.0 kgf*cm, 9.0 to 15.0 in.*lbf)
      Reused bearing
      0.56 to 0.85 N*m (6.0 to 9.0 kgf*cm, 5.0 to 8.0 in.*lbf)

      Note

      Record the preload for total preload measurement.

      If the preload is not within the specified range, adjust the differential drive pinion preload or repair as necessary.

  10. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. Install the case bearing outer races LH and RH to the case bearing inner races LH and RH respectively.

      Note

      Be sure to install the bearing outer races in each correct position.

    2. A01BGG9

      Install the differential case to the differential carrier.

      Tech Tips

      Make sure the right and left races are not interchanged.

  11. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT


    1. A01BGPH

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

    2. A01BBPGE01

      Align the matchmarks on the bearing 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 not fit tightly on the carrier, the adjusting nuts are not threaded properly. Reinstall the adjusting nuts if necessary.

  12. ADJUST DIFFERENTIAL RING GEAR BACKLASH


    1. A01BAARE01

      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.

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

    2. Using the SST and dial indicator, tighten the adjusting nut on the ring gear back surface side so that the backlash of the ring is about 0.18 mm (0.0071 in.).

      SST
      09504-00011
    3. A01BC1HE01

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

      SST
      09504-00011

    4. Using SST, tighten the adjusting nut on the ring gear tooth side until the free play of the adjusting nut becomes 0.

      Note

      The free play becomes 0 when the adjusting nut becomes difficult to tighten.

    5. A01BBCGE01
      Text in Illustration
      *a 1 notch

      Tighten the adjusting nut on the ring gear tooth side 1.5 notches as shown in the illustration to apply preload to the side bearing.

      Tech Tips

      1 hole is equivalent to 1 notch.

    6. A01BGKQE01

      Adjust the backlash between the drive pinion and ring gear to within the standard range by moving the bearing using the left and right adjusting nuts. (Tighten the right adjusting nut 1 notch for each notch loosened with the left nut.)

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

      Note


      • Tighten the right adjusting nut 1 notch for each notch loosened with the left nut in order to maintain the side bearing preload.

      • Measure the backlash at 3 or more points on the circumference of the ring gear.

      • Align the adjusting nut lock hole and adjusting nut hole.

    7. A01BBPGE01

      Torque the 4 bearing cap bolts.

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

  13. INSPECT TOTAL PRELOAD


    1. A01BFEV

      Using a socket wrench (30 mm) and torque wrench, measure the preload.

      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)

      If the preload is not within the specified range, adjust it by the bearing adjusting nut on the ring gear teeth side.

  14. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01BGOJ

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

    2. Rotate the ring gear in both directions.

    3. Inspect the tooth contact pattern.

      A01BHYME01
    4. A01BEIRE01

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

      Plate washer thickness
      Thickness mm (in.) Thickness mm (in.)
      1.69 to 1.71 (0.0665 to 0.0673) 2.02 to 2.04 (0.0795 to 0.0803)
      1.72 to 1.74 (0.0677 to 0.0685) 2.05 to 2.07 (0.0807 to 0.0815)
      1.75 to 1.77 (0.0689 to 0.0697) 2.08 to 2.10 (0.0819 to 0.0827)
      1.78 to 1.80 (0.0701 to 0.0709) 2.11 to 2.13 (0.0831 to 0.0839)
      1.81 to 1.83 (0.0713 to 0.0720) 2.14 to 2.16 (0.0843 to 0.0850)
      1.84 to 1.86 (0.0724 to 0.0732) 2.17 to 2.19 (0.0854 to 0.0862)
      1.87 to 1.89 (0.0736 to 0.0744) 2.20 to 2.22 (0.0866 to 0.0874)
      1.90 to 1.92 (0.0748 to 0.0756) 2.23 to 2.25 (0.0878 to 0.0886)
      1.93 to 1.95 (0.0760 to 0.0768) 2.26 to 2.28 (0.0890 to 0.0898)
      1.96 to 1.98 (0.0772 to 0.0780) 2.29 to 2.31 (0.0902 to 0.0909)
      1.99 to 2.01 (0.0783 to 0.0791) 2.32 to 2.34 (0.0913 to 0.0921)

  15. REMOVE REAR DRIVE PINION NUT


    1. A01BCELE01

      Using SST, hold the flange.

      SST
      09330-00021

    2. Using a socket wrench (30 mm), remove the drive pinion nut.

  16. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01BE47E01

      Using SST, remove the companion flange.

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

      Note

      Apply grease to the threads and tip of the SST center bolt before use.

  17. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01BBKXE01

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

      SST
      09556-22010

      Note

      Apply grease to the threads and tip of the SST center bolt before use.

    2. A01BE7RE02

      Using SST, remove the outer race of the rear drive pinion front tapered roller bearing from the differential carrier.

      SST
      09308-00010

  19. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01BDC0

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

      Note

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

  20. INSTALL DIFFERENTIAL OIL STORAGE RING


    1. Using a brass bar and hammer, tap in a new oil storage ring.

      Note

      Be careful not to damage the oil storage ring.

  21. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01BGNME01

      Using SST and hammer, tap in the outer race of the rear drive pinion front tapered roller bearing.

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

    2. Install the inner race of the rear drive pinion front tapered roller bearing.

  22. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  23. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01BE93E01

      Using SST and a hammer, install a new oil seal.

      SST
      09554-22010
      Oil seal drive in depth
      0.55 to 1.45 mm (0.0217 to 0.0571 in.)

    2. Apply MP grease to the oil seal lip.

  24. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01BCJWE01

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

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

      Note

      Apply grease to the threads and tip of the SST center bolt before use.

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

    3. A01BBXEE01

      Using SST, hold the flange.

      SST
      09330-00021

    4. Using a socket wrench (30 mm) and torque wrench, gradually tighten the drive pinion nut within the adjustment range of the differential drive pinion preload.

      Torque
      370 N*m (3,770 kgf*cm, 273 ft.*lbf) or less

  25. INSPECT DRIVE PINION PRELOAD


    1. A01BB9R

      Turn the bearing clockwise and counterclockwise several times to stabilize it.

    2. Using a socket wrench (30 mm) and torque wrench, measure the preload.

      Preload (at starting)
      New bearing
      1.05 to 1.64 N*m (11.0 to 17.0 kgf*cm, 9.0 to 15.0 in.*lbf)
      Reused bearing
      0.56 to 0.85 N*m (6.0 to 9.0 kgf*cm, 5.0 to 8.0 in.*lbf)

    3. 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.

    4. 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.

    5. 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.

  26. INSPECT TOTAL PRELOAD


    1. A01BB9R

      Using a socket wrench (30 mm) and torque wrench, measure the preload.

      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)

  27. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. Set the dial indicator to the end of the differential ring gear face.

    2. A01BANM

      Rotate the differential ring gear and measure the backlash.

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

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


    1. A01BFG6E01

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

      Maximum runout
      0.09 mm (0.0035 in.)

      If the runout is greater than the maximum value, replace the companion flange sub-assembly.

  29. INSTALL REAR DRIVE PINION NUT


    1. A01BCOP

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

  30. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01BHXGJ01

      Install the 2 bearing adjusting nut locks to the bearing caps.

    2. Tighten both of the bearing adjusting nut locks with the 2 bolts.

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