DIFFERENTIAL CARRIER ASSEMBLY REASSEMBLY


  1. ASSEMBLE DIFFERENTIAL CASE (for 2 Pinion Gear Type)


    1. A01DX6F

      Install the side gear thrust washer to the side gear.

      Tech Tips

      Using the table below, select 2 thrust washers which will ensure that the backlash is within the specifications.

      Standard Washer Thickness
      Thickness mm (in.) Thickness mm (in.)
      1.48 to 1.52 (0.0583 to 0.0598) 1.73 to 1.77 (0.0682 to 0.0696)
      1.53 to 1.57 (0.0603 to 0.0618) 1.78 to 1.82 (0.0701 to 0.0716)
      1.58 to 1.62 (0.0622 to 0.0637) 1.83 to 1.87 (0.0721 to 0.0736)
      1.63 to 1.67 (0.0642 to 0.0657) 1.88 to 1.92 (0.0741 to 0.0755)
      1.68 to 1.72 (0.0662 to 0.0677) -
    2. A01E0UI

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

      Tech Tips

      Align the holes of the differential case and pinion shaft.

    3. A01DYNA

      Measure the side gear backlash.


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

        Backlash
        0.05 to 0.20 mm (0.00197 to 0.00787 in.)

        • If the backlash is not as specified, install 2 side gear thrust washers with different thicknesses.

    4. A01E2BY

      Using a pin punch and hammer, tap in the straight pin through the differential case and hole of the pinion shaft.

    5. Stake the differential case.

  2. ASSEMBLE DIFFERENTIAL CASE (for LSD)


    1. A01E30UE01
      Text in Illustration
      *1 Case RH
      *2 Case LH

      Measure the differential case dimension labeled A.

    2. Install the thrust washers and clutch plates on the side gear.

    3. A01DVILE01

      Using SST to press down the thrust washers and clutch plates with a force of approximately 98 N*m (1000 kgf*cm, 72 ft.*lbf), measure dimension "B" shown in the illustration.

      SST
      09649-17010

    4. Referring to the following table, select the proper adjusting shim.

      Adjusting shim thickness
      Adjusting shim thickness = A - B - 16.175 mm (0.637 in.)
      Thickness mm (in.) Thickness mm (in.)
      1.83 to 1.89 (0.0721 to 0.0744) 2.19 to 2.25 (0.0863 to 0.0885)
      1.89 to 1.95 (0.0745 to 0.0767) 2.25 to 2.31 (0.0886 to 0.0909)
      1.95 to 2.01 (0.0768 to 0.0791) 2.31 to 2.37 (0.0910 to 0.0933)
      2.01 to 2.07 (0.0792 to 0.0814) 2.37 to 2.43 (0.0934 to 0.0956)
      2.07 to 2.13 (0.0815 to 0.0838) 2.43 to 2.49 (0.0957 to 0.0980)
      2.13 to 2.19 (0.0839 to 0.0862) -
    5. A01DWAGE01

      Install the following parts to the differential cases.


      • (1) Side gear thrust washer

      • (2) Clutch plate

      • (3) No. 1 side gear thrust washer

      • (4) Side gear

    6. A01DXQB

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

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

    8. Install the pinion gears and spider to the differential RH case.

      Tech Tips

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

    9. A01E0T1

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

      Backlash
      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

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

        Tech Tips


        • Measure at all 4 locations.


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

    10. Reinstall the spider to the RH case tightly and do not move the spring retainer.

    11. Install the compression spring and spring LH retainer.

    12. A01E2W4

      Install the side gear, thrust washers and clutch plates.

    13. 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. A01DYF0E01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the differential case RH and differential case LH.

    15. Install the 8 bolts by diametrically tightening the bolts uniformly in several passes.

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

  3. INSTALL DIFFERENTIAL RING GEAR


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

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

    3. Carefully remove the ring gear from the boiling water.

    4. A01DXV8E01
      Text in Illustration
      *1 Matchmark

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

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

    6. After the ring gear cools down, install the 10 bolts by diametrically tightening the bolts uniformly in several passes.

      Torque:
      87 N*m  { 891 kgf*cm, 64 ft.*lbf }
    7. A01DUXIE01

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

      Tech Tips

      Strike the tab labeled A so that it is flush with the flat surface of the bolt. Strike the tab labeled B so that half of the tab contacts the bolt as shown in the illustration.

  4. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01DXDSE01
      Text in Illustration
      *A for LSD
      *B 2 Pinion Type

      Using SST and a press, press the bearing onto the differential case.

      SST
      09950-60010   ( 09951-00430, 09951-00470, 09951-00480, 09951-00550 )
      09950-70010   ( 09951-00560, 09951-00570, 09951-07150 )

  5. INSPECT DIFFERENTIAL RING GEAR RUNOUT


    1. Install the differential case on the 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. A01E2JX

      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.

  6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01DWSWE01

      Using SST and a press, press the roller bearing (outer) to the carrier.

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

  7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01DYJ6E01

      Using SST and a press, press the roller bearing (outer) into the carrier.

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

  8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. Install the plate washer to the drive pinion.

      Tech Tips

      First, install a washer that has the same thickness as the removed washer. After checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.

    2. A01E0DDE01

      Using SST and a press, press the roller bearing (inner) onto the drive pinion.

      SST
      09506-30012

  9. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01E2PU

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

      Tech Tips

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

    2. A01DZADE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the 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. A01DVPTE01

      Adjust the drive pinion preload by tightening the companion flange nut.

    4. Using SST to hold the companion flange in place, tighten the nut.

      SST
      09330-00021   ( 09330-00030 )
      Torque:
      370 N*m  { 3773 kgf*cm, 273 ft.*lbf, or less }

      Note


      • As there is no spacer, tighten a little at a time. Be careful not to overtighten the nut.

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

    5. Using a torque wrench, measure the preload.

      Standard Drive Pinion Preload (Starting Torque)
      Bearing Preload
      New bearing 1.0 to 1.5 N*m (11 to 15 kgf*cm, 9 to 13 in.*lbf)
      Reused bearing 0.5 to 0.7 N*m (6 to 7 kgf*cm, 5 to 6 in.*lbf)

      Note


      • For a more accurate measurement, rotate the bearing forward and backward several times before measuring.

      • Record the differential drive pinion preload for the total preload measurement.

  10. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. A01DXY5

      Place the 2 bearing outer races to their respective bearings.

      Tech Tips

      Make sure the right and left races are not interchanged.

  11. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT


    1. A01E2GX

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

  12. INSPECT AND ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH


    1. A01DYE9E01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the cap and carrier.

    2. A01E0TH

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

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

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

        Tech Tips

        Reinstall the adjusting nuts if necessary.

    3. A01DZOHE01
      Text in Illustration
      *a for LH Side
      *b for RH Side

      Loosen the 4 bearing cap bolts to the point where the adjusting nuts can be turned by SST.

    4. Using SST, torque the adjusting nut on the ring gear side until the ring gear has a backlash of about 0.2 mm (0.00787 in.).

      SST
      09504-00011
      09960-10010   ( 09962-01000, 09963-00700 )

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

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

      SST
      09504-00011
      09960-10010   ( 09962-01000, 09963-00700 )
    7. A01E2IQE01

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

      Standard backlash
      0.13 to 0.18 mm (0.00512 to 0.00708 in.)

      Tech Tips


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

      • Perform the measurement at 3 or more positions around the circumference of the ring gear.

    8. A01E1VV

      Tighten the bearing cap bolts.

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

  13. INSPECT TOTAL PRELOAD


    1. A01DWNB

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

    2. Using a torque wrench, measure the total preload.

      Standard Total Preload
      Item Specified Condition
      New bearing 0.4 to 0.5 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) + drive pinion preload
      Reused bearing 0.4 to 0.5 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) + drive pinion preload

      If necessary, disassemble and inspect the differential.

      Note

      Record the differential ring gear preload.

  14. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01DVD9

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

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

    3. Inspect the tooth contact pattern.


      • A01DZDJE01
      • A01DY8NE01
        Text in Illustration
        *1 Plate Washer

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

        Standard Plate Washer Thickness
        Thickness mm (in.) Thickness mm (in.)
        1.69 to 1.71 (0.0666 to 0.0673) 2.02 to 2.04 (0.0796 to 0.0803)
        1.72 to 1.74 (0.0678 to 0.0685) 2.05 to 2.07 (0.0807 to 0.0814)
        1.75 to 1.77 (0.0689 to 0.0696) 2.08 to 2.10 (0.0819 to 0.0826)
        1.78 to 1.80 (0.0701 to 0.0708) 2.11 to 2.13 (0.0831 to 0.0838)
        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 (0.0725 to 0.0732) 2.17 to 2.19 (0.0855 to 0.0862)
        1.87 to 1.89 (0.0737 to 0.0744) 2.20 to 2.22 (0.0867 to 0.0874)
        1.90 to 1.92 (0.0748 to 0.0755) 2.23 to 2.25 (0.0878 to 0.0885)
        1.93 to 1.95 (0.0760 to 0.0767) 2.26 to 2.28 (0.0890 to 0.0897)
        1.96 to 1.98 (0.0772 to 0.0779) 2.29 to 2.31 (0.0902 to 0.0909)
        1.99 to 2.01 (0.0784 to 0.0791) 2.32 to 2.34 (0.0914 to 0.0921)

  15. REMOVE REAR DRIVE PINION NUT


    1. A01DVN5E01

      Using SST and a hammer, loosen the staked part of the nut.

      SST
      09930-00010   ( 09931-00010, 09931-00020 )
    2. A01DWE9E01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the companion flange in place, remove the nut.

      SST
      09330-00021   ( 09330-00030 )

  16. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY WITH DUST DEFLECTOR


    1. A01DW9H

      Using SST, remove the companion flange with dust deflector.

      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.

  17. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01DZDA

      Remove the oil slinger from the drive pinion.

  18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01E1CNE01

      Using SST, remove the roller bearing (inner) from the drive pinion.

      SST
      09556-22010

  19. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01DZDP

      Install a new bearing spacer.

      Tech Tips

      Make sure the spacer is installed correctly.

  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. A01E0HQ

      Install the bearing (inner) to the drive pinion.

  22. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01DZDA

      Install the oil slinger to the drive pinion.

  23. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01E0NVE01
      Text in Illustration
      *a Oil Seal Depth

      Using SST and a hammer, tap in a new oil seal.

      SST
      09554-30011
      Standard oil seal depth
      0 +/-0.3mm (0 +/-0.0118in.)

    2. Apply MP grease to the lip of the oil seal.

  24. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY WITH DUST DEFLECTOR


    1. A01DZYZ

      Using SST, install the companion flange with dust deflector.

      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 nut seat face.

    3. A01DVBQE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the companion flange in place, install a new nut.

      SST
      09330-00021   ( 09330-00030 )
      Torque:
      370 N*m  { 3773 kgf*cm, 273 ft.*lbf, or less }

  25. INSPECT TOTAL PRELOAD


    1. A01DWNB

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

    2. Using a torque wrench, measure the total preload.

      Standard Total Preload
      Bearing Preload
      New bearing 1.1 to 1.6 N*m (12 to 16 kgf*cm, 10 to 14 in.*lbf) + ring gear preload
      Reused bearing 0.6 to 0.8 N*m (7 to 8 kgf*cm, 6 to 7 in.*lbf) + ring gear preload

      • If necessary, disassemble and inspect the differential.

  26. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01DX8D

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

      Standard backlash
      0.13 to 0.18 mm (0.00512 to 0.00708 in.)

      • If the backlash is not as specified, adjust the side bearing preload or perform repairs as necessary.

        Tech Tips

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

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


    1. A01E280E01
      Text in Illustration
      *a 30 mm (1.18 in.)

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

      Maximum Runout
      Runout Maximum
      Vertical runout 0.10 mm (0.00394 in.)
      Lateral runout 0.10 mm (0.00394 in.)

      • If the runout is more than the maximum, replace the companion flange.

  28. STAKE DRIVE PINION NUT


    1. A01DW40

      Using a chisel and hammer, stake the nut.

  29. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01DZJK

      Install 2 new adjusting nut locks to the bearing caps with the 2 bolts.

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

    2. Bend the nut locks.