REAR DIFFERENTIAL CARRIER ASSEMBLY INSPECTION


  1. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. A0160J2E01

      Set the dial indicator perpendicular to the end of the ring gear face.

    2. Rotate the ring gear and measure the backlash.

      Maximum runout
      0.04 mm (0.00157 in.)

      If the runout exceeds the specified maximum value, remove the ring gear and check the runout of the differential case.

  2. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A016030E01

      While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

      Backlash
      0.08 to 0.13 mm (0.00315 to 0.00512 in.)

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

  3. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A0162BM

      Coat 3 or 4 teeth at the 3 different positions on the ring gear with prussian blue.

    2. Rotate the ring gear in both directions.

    3. Inspect the tooth contact pattern.

      A015ZRUE03
    4. A01639BE01

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

      Tech Tips


      • If the contact pattern is face contact or flank contact, tooth contact may be adjustable while keeping the backlash within the specified range.

      • If the thickness of the drive pinion washer has been changed, adjust the backlash and measure the total preload.

      Washer Thickness
      Thickness mm (in.) No. Thickness mm (in.) No. Thickness mm (in.) No.
      1.87 (0.0736) 87 2.01 (0.0791) 01 2.15 (0.0846) 15
      1.88 (0.0740) 88 2.02 (0.0795) 02 2.16 (0.0850) 16
      1.89 (0.0744) 89 2.03 (0.0799) 03 2.17 (0.0854) 17
      1.90 (0.0748) 90 2.04 (0.0803) 04 2.18 (0.0858) 18
      1.91 (0.0752) 91 2.05 (0.0807) 05 2.19 (0.0862) 19
      1.92 (0.0756) 92 2.06 (0.0811) 06 2.20 (0.0866) 20
      1.93 (0.0760) 93 2.07 (0.0815) 07 2.21 (0.0870) 21
      1.94 (0.0764) 94 2.08 (0.0819) 08 2.22 (0.0874) 22
      1.95 (0.0768) 95 2.09 (0.0823) 09 2.23 (0.0878) 23
      1.96 (0.0772) 96 2.10 (0.0827) 10 2.24 (0.0882) 24
      1.97 (0.0776) 97 2.11 (0.0831) 11 2.25 (0.0886) 25
      1.98 (0.0780) 98 2.12 (0.0835) 12 2.26 (0.0890) 26
      1.99 (0.0783) 99 2.13 (0.0839) 13 2.27 (0.0894) 27
      2.00 (0.0787) 00 2.14 (0.0843) 14 2.28 (0.0898) 28

  4. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A0162J6

      Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0.15 mm (0.00591 in.) or less.

      If not, replace the rear differential case sub-assembly with a new one.

  5. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A0160GL

      Secure the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Place a dial indicator on the tip of the side gear tooth at a right angle. Hold the pinion gear in the differential case and check that the backlash is 0.15 mm (0.00591 in.) or less.

      If not, replace the rear differential case sub-assembly with a new one.

  6. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION


    1. A0160XK

      Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.394 in.) away from the end of the shaft.

      Maximum runout
      0.08 mm (0.00315 in.)

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

  7. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01606GE01

      Using SST and a torque wrench, measure the starting torque of the drive pinion. The backlash between the drive pinion and ring gear should allow enough movement of the drive pinion to allow this measurement to be performed. Make sure not to include the preload of the ring gear (differential case) in the measurement of the drive pinion preload.

      Differential Drive Pinion Preload (at Starting)
      A Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.25 to 1.65 N*m (12.75 to 16.83 kgf*cm, 11.06 to 14.60 in.*lbf)
      Used rear drive pinion tapered roller bearing 1.25 to 1.65 N*m (12.75 to 16.83 kgf*cm, 11.06 to 14.60 in.*lbf)
      B Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.44 to 2.01 N*m (14.68 to 20.50 kgf*cm, 12.74 to 17.79 in.*lbf)
      Used rear drive pinion tapered roller bearing 0.50 to 0.80 N*m (5.10 to 8.16 kgf*cm, 4.43 to 7.08 in.*lbf)

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

  8. INSPECT TOTAL PRELOAD


    1. A01606GE01

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

      Total Preload (at Starting)
      A Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.91 to 3.51 N*m (19.48 to 35.79 kgf*cm, 16.90 to 31.07 in.*lbf)
      Used rear drive pinion tapered roller bearing 1.74 to 2.96 N*m (17.74 to 30.18 kgf*cm, 15.40 to 26.20 in.*lbf)
      B Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 2.10 to 3.87 N*m (21.41 to 39.46 kgf*cm, 18.59 to 34.25 in.*lbf)
      Used rear drive pinion tapered roller bearing 0.99 to 2.11 N*m (10.10 to 21.52 kgf*cm, 8.76 to 18.67 in.*lbf)

  9. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY

    Tech Tips

    Perform this procedure only when the runout of the differential ring gear exceeds the specified maximum value.


    1. A0163DU

      Install the differential case to the differential carrier.

      Note

      Do not damage the case bearing.

    2. A015ZVOE01

      Using SST and a hammer, install the differential side bearing outer race RH on the ring gear tooth side.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      Tap in the differential side bearing outer race RH until half of the side gear shaft snap ring groove of the differential carrier can be seen.

    3. A0162JCE01

      Install SST to the differential carrier with the 2 bolts.

      SST
      09571-50010

    4. Tighten the SST bolt (A) until the SST disc lightly touches the differential side bearing outer race RH.

    5. A0160YOE01

      Using SST and a hammer, install the differential side bearing outer race LH on the ring gear back surface side.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      Tap in the differential side bearing outer race LH until it touches the case bearing inner race roller.

    6. A0162TQ

      Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.

    7. Place a dial indicator on the differential case flange surface at a right angle.

    8. A015ZG2E01

      Using a dial indicator, measure the differential case runout.

      Maximum runout
      0.04 mm (0.00157 in.)

      If the runout is greater than the maximum, replace the rear differential case with a new one.

    9. A0162TQ

      Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.

    10. A0162NKE01

      Tighten the SST bolt to push out the ring gear back surface side differential side bearing outer race LH.

      Note

      Do not drop the differential side bearing outer race LH.

    11. A0160DFE01

      Remove the 2 bolts and SST.

    12. A0160X2E01

      Raise the ring gear side of the differential case slightly to remove the ring gear tooth side differential side bearing outer race RH.

    13. A0162RL

      Remove the differential case from the differential carrier as shown in the illustration.

      Note

      Do not damage the case bearing.