DIFFERENTIAL CARRIER ASSEMBLY (for DANA Made) REASSEMBLY


  1. INSTALL DIFFERENTIAL RING GEAR

    A01DWINE02

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

    5. A01DV33E01

      Align the matchmarks on the ring gear with those of the differential case.

    6. Temporarily install the 10 bolts.

    7. After the ring gear cools down, uniformly tighten the 10 bolts in diametrically opposite pairs in several passes.

      Torque:
      160 to 180 N*m  { 1,632 to 1835 kgf*cm, 118 to 133 ft.*lbf }

  2. INSTALL REAR DIFFERENTIAL CASE BEARING


    1. A01DZICE01

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

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

  3. INSPECT DIFFERENTIAL RING GEAR RUNOUT


    1. Install the differential case on the carrier, and install the 2 side shims 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. A01DYGR

      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 side shims and differential case.

  4. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR


    1. A01E224E01

      Using SST, a plate and a press, press in the dust deflector.

      SST
      09636-20010

      Note

      Be careful not to damage the dust deflector.

  5. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01DY4ZE01

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

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

  6. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01DWQHE01

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

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

  7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. Install the plate washer on the drive pinion.

      Tech Tips

      First fit a washer with the same thickness as the removed washer, and then check the tooth contact pattern. Replace the washer with one of a different thickness if necessary.

    2. A01DWMLE02

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

      SST
      09506-30012

  8. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01DYGPE01

      Install a new bearing spacer to the drive pinion.

    2. A01E2GTE01

      Install the rear drive pinion front tapered roller bearing.

    3. Install the rear differential drive pinion oil slinger.

    4. Apply MP grease to a new oil seal.

    5. A01DY0IE03

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

      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.

    6. A01DZKCE03

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

      SST
      09330-00021   ( 09330-00030 )
    7. A01DZXUE01

      Using a torque wrench, measure the preload.

      Standard preload (at start of torque)
      Bearing Preload
      New bearing 1.05 to 1.64 N*m (10.7 to 16.7 kgf*cm, 9.3 to 14.5 in.*lbf)
      Reused bearing 0.56 to 0.85 N*m (5.7 to 8.7 kgf*cm, 4.9 to 7.5 in.*lbf)

      • If the preload is greater than the maximum, replace the bearing spacer.

      • If the preload is less than the minimum, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached.

      Torque:
      678 N*m  { 6,914 kgf*cm, 500 ft.*lbf }

      • If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure.

        Tech Tips

        Do not loosen the pinion nut to reduce the preload.

  9. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. A01DVCXE01

      Place the 2 bearing outer races on their respective bearings and 2 side shims.

      Tech Tips

      Make sure the right and left races are not interchanged.

    2. A01DZP9

      Align matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps.

      Note

      Make sure the right and left bearing caps are not interchanged.

    3. Tighten both bearing caps with the 4 bolts.

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

  10. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH

    A01DZSO
    SST
    09504-00011
    09960-10010   ( 09962-01000, 09963-00700 )

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

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

      Standard backlash
      0.13 to 0.20 mm (0.0051 to 0.0078 in.)

  11. ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH


    1. A01DWGT

      Select a side shim so that the ring gear backlash is within the specification. Then, install it to the ring gear back side.

      Tech Tips


      • If the case bearing is new, select a thinner side shim and install it.

      • If the case bearing is reused, install a side shim with the same thickness as the removed one.

        Standard side shim thickness
        Thickness Thickness Thickness
        2.51 mm (0.099 in.) 3.12 mm (0.123 in.) 3.73 mm (0.147 in.)
        2.54 mm (0.100 in.) 3.15 mm (0.124 in.) 3.76 mm (0.148 in.)
        2.57 mm (0.101 in.) 3.18 mm (0.125 in.) 3.78 mm (0.149 in.)
        2.59 mm (0.102 in.) 3.20 mm (0.126 in.) 3.81 mm (0.150 in.)
        2.62 mm (0.103 in.) 3.23 mm (0.127 in.) 3.84 mm (0.151 in.)
        2.64 mm (0.104 in.) 3.25 mm (0.128 in.) 3.86 mm (0.152 in.)
        2.67 mm (0.105 in.) 3.28 mm (0.129 in.) 3.89 mm (0.153 in.)
        2.69 mm (0.106 in.) 3.30 mm (0.130 in.) 3.91 mm (0.154 in.)
        2.72 mm (0.107 in.) 3.33 mm (0.131 in.) 3.94 mm (0.155 in.)
        2.74 mm (0.108 in.) 3.35 mm (0.132 in.) 3.96 mm (0.156 in.)
        2.77 mm (0.109 in.) 3.38 mm (0.133 in.) 3.99 mm (0.157 in.)
        2.79 mm (0.110 in.) 3.40 mm (0.134 in.) 4.01 mm (0.158 in.)
        2.82 mm (0.111 in.) 3.43 mm (0.135 in.) 4.04 mm (0.159 in.)
        2.84 mm (0.112 in.) 3.45 mm (0.136 in.) 4.06 mm (0.160 in.)
        2.87 mm (0.113 in.) 3.48 mm (0.137 in.) 4.09 mm (0.161 in.)
        2.90 mm (0.114 in.) 3.51 mm (0.138 in.) 4.11 mm (0.162 in.)
        2.92 mm (0.115 in.) 3.53 mm (0.139 in.) 4.14 mm (0.163 in.)
        2.95 mm (0.116 in.) 3.56 mm (0.140 in.) 4.17 mm (0.164 in.)
        2.97 mm (0.117 in.) 3.58 mm (0.141 in.) 4.19 mm (0.165 in.)
        3.00 mm (0.118 in.) 3.61 mm (0.142 in.) 4.22 mm (0.166 in.)
        3.02 mm (0.119 in.) 3.63 mm (0.143 in.) 4.24 mm (0.167 in.)
        3.05 mm (0.120 in.) 3.66 mm (0.144 in.) 4.27 mm (0.168 in.)
        3.07 mm (0.121 in.) 3.68 mm (0.145 in.) 4.29 mm (0.169 in.)
        3.10 mm (0.122 in.) 3.71 mm (0.146 in.) -

    2. Make the differential case bearing and side shim snug by tapping on the ring gear with a plastic-faced hammer.

    3. A01DZSO

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

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

      Standard backlash
      0.13 to 0.20 mm (0.0051 to 0.0078 in.)
    5. A01DWGT

      If the backlash is not within the specification, select a side shim so that the ring gear backlash is within the specification. Then, install it to the ring gear back side.

    6. A01DZTTE01

      Select a thicker side shim so that the clearance between the case bearing outer race end on the ring gear teeth side and the carrier becomes 0 or around 0.

    7. Make the differential case bearing and side shim snug by tapping on the ring gear with a plastic-faced hammer.

    8. A01DYKF

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

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

      Standard backlash
      0.13 to 0.20 mm (0.0051 to 0.0078 in.)

      • If the backlash is not within the specification, adjust the thickness of the right and left side shim by an equal amount so that the backlash is within the specification.

  12. INSPECT TOTAL PRELOAD


    1. A01DZTFE01

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

      Tech Tips

      A bolt without a torque specification is shown in the service data Click here.


      • If necessary, disassemble and inspect the differential.

  13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01DWWWE01

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

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

    3. Inspect the tooth contact pattern.


      • A01DZDJE01
      • A01E2TCE03

        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.)
        0.69 mm (0.0272 in.) 1.19 mm (0.0469 in.)
        0.71 mm (0.0280 in.) 1.22 mm (0.0480 in.)
        0.74 mm (0.0291 in.) 1.24 mm (0.0488 in.)
        0.76 mm (0.0300 in.) 1.27 mm (0.0500 in.)
        0.79 mm (0.0311 in.) 1.30 mm (0.0512 in.)
        0.81 mm (0.0319 in.) 1.32 mm (0.0520 in.)
        0.84 mm (0.0331 in.) 1.35 mm (0.0531 in.)
        0.86 mm (0.0339 in.) 1.37 mm (0.0540 in.)
        0.89 mm (0.0350 in.) 1.40 mm (0.0551 in.)
        0.91 mm (0.0358 in.) 1.42 mm (0.0559 in.)
        0.94 mm (0.0370 in.) 1.45 mm (0.0571 in.)
        0.97 mm (0.0382 in.) 1.47 mm (0.0579 in.)
        0.99 mm (0.0390 in.) 1.50 mm (0.0591 in.)
        1.02 mm (0.0402 in.) 1.52 mm (0.0598 in.)
        1.04 mm (0.0409 in.) 1.55 mm (0.0610 in.)
        1.07 mm (0.0421 in.) 1.58 mm (0.0622 in.)
        1.09 mm (0.0429 in.) 1.60 mm (0.0630 in.)
        1.12 mm (0.0441 in.) 1.63 mm (0.0642 in.)
        1.14 mm (0.0449 in.) 1.65 mm (0.0650 in.)
        1.17 mm (0.0461 in.) -

  14. 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 )

  15. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

  16. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  17. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01E1CNE01

      Using SST, remove the roller bearing (inner).

      SST
      09556-22010
    2. A01E30HE01

      Using SST, tap out the roller bearing (outer).

      SST
      09308-00010

  18. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01DYGPE01

      Install a new bearing spacer to the drive pinion.

  19. 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.

  20. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    A01E2GTE01

  21. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL


    1. Apply MP grease to the lip of a new oil seal.

    2. Using a brass bar and hammer, tap in a new oil seal until its surface is flush with the differential carrier end.

      Note

      Do not damage the oil seal.

  23. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01DY0IE05

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

      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. A01DZKCE03

      Using SST to hold the flange, torque the nut.

      SST
      09330-00021   ( 09330-00030 )
      Torque:
      370 N*m  { 3,770 kgf*cm, 273 ft.*lbf, or less }

  24. INSPECT DRIVE PINION PRELOAD


    1. A01DZXUE01

      Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

      Standard preload (at start of torque)
      Bearing Preload
      New bearing 1.20 to 2.00 N*m (12 to 20 kgf*cm, 11 to 18 in.*lbf)
      Reused bearing 0.70 to 1.50 N*m (7 to 15 kgf*cm, 6.0 to 13 in.*lbf)

      • If the preload is greater than the maximum, replace the bearing spacer.


      • If the preload is less than the minimum, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached.

      Torque:
      678 N*m  { 6,914 kgf*cm, 500 ft.*lbf, or less }

      • If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure.

      Tech Tips

      Do not loosen the pinion nut to reduce the preload.

  25. INSPECT TOTAL PRELOAD


    1. A01DZXUE01

      Using a torque wrench, measure the preload.

      Tech Tips

      A bolt without a torque specification is shown in the service data Click here.


      • If necessary, disassemble and inspect the differential.

  26. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01DZSO

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

      Standard backlash
      0.13 to 0.20 mm (0.0051 to 0.0078 in.)

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

        Tech Tips

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

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


    1. A01DYNLE03

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

      Maximum runout
      Runout Maximum
      Vertical runout 0.10 mm (0.0039 in.)
      Lateral runout 0.10 mm (0.0039 in.)

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

  28. STAKE DRIVE PINION NUT


    1. A01DUZ9E01

      Using a chisel and hammer, stake the nut.