Front Differential
DISASSEMBLY
1. Remove differential carrier cover.
a. Remove the 9 bolts from the carrier cover.
b. Using a brass bar and hammer, separate the cover from carrier.
c. Remove the breather plug from the differential carrier cover.
d. Remove the 2 bolts and oil deflector from the differential carrier cover.
2. Set differential carrier to overhaul stand etc.
3. Check runout of companion flange.
Using a dial indicator, measure the vertical and lateral runout of the companion flange.
Maximum: 0.09 mm (0.0035 inch)
If the runout is greater than the maximum, replace the companion flange.
4. Check ring gear runout.
Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.07 mm (0.0028 inch)
If the runout is greater than the maximum, replace the ring gear and drive pinion as a set.
5. Check ring gear backlash.
Using a dial indicator, while holding the drive pinion flange measure the ring gear backlash.
Backlash: 0.13-0.18 mm (0.0051-0.0071 inch)
HINT:
- Measure at 3 or more places on the circumference of the ring gear.
- If the backlash is not within the specification, adjust the backlash.
6. Measure drive pinion preload.
Using a torque wrench, measure the drive pinion preload using the backlash of the drive pinion and ring gear.
Preload (at starting): 0.5-0.8 Nm (4.3-6.9 inch lbs.)
7. Check total preload.
Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus: 0.4-0.6 Nm (3.5-5.2 inch lbs.)
If necessary, disassemble and inspect the differential.
8. Inspect tooth contact between ring gear and drive pinion.
a. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.
b. Hold the companion flange firmly and rotate the ring gear in both directions.
c. Inspect the tooth contact pattern.
9. Check side gear backlash.
Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.
Maximum backlash: 0.15 mm (0.0059 inch)
If the backlash is out of the specification, install the correct thrust washers as outlined under step 1 of "Reassembly."
10. Remove side gear shaft oil seals.
Using Special Service Tool (SST) 09308-00010 or equivalent, remove the 2 side gear shaft oil seals.
11. Remove differential tube assembly.
a. Using SST 09350-30020 (09350-07060), remove the snap ring.
b. Using a snap ring expander, remove the snap ring.
c. Remove the 4 bolts and differential tube with side gear shaft from the differential carrier.
d. Remove the side gear shaft from the differential tube.
12. Remove side gear bearing.
Using SST 09950-60010 (09951 -00410), 09950-70010 (09951-07100) and a press, remove the bearing from side gear shaft.
13. Remove companion flange.
a. Using a chisel and hammer, unstake the nut.
b. Using SST 09330-00021 to hold the flange, remove the nut.
c. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020), remove the companion flange.
14. Remove oil seal and oil slinger.
a. Using SST 09308-10010, remove the oil seal from the differential carrier.
b. Remove the oil slinger.
15. Remove rear bearing.
Using SST 0955-22010, remove the rear bearing from the drive pinion.
If the rear bearing is damaged or worn, replace the rear bearing.
16. Remove differential case assembly.
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 4 bolts and 2 bearing caps.
c. Using SST 09504-22011 and a hammer, remove the 2 side bearing plate washers.
HINT: Measure the plate washer and note down the thickness.
d. Remove the differential case with the bearing outer races from the differential carrier.
HINT: Tag the bearing outer races to show the location for reassembling.
17. Remove drive pinion and bearing spacer from differential carrier.
18. Remove drive pinion front bearing.
a. Using SST 09950-00020 and a press, remove the front bearing from the drive pinion.
HINT: If the drive pinion or ring gear is damaged, replace them as a set.
b. Remove the washer.
19. Remove drive pinion front and rear bearing outer races and oil storage ring.
a. Using SST 09308-00010, remove the rear bearing outer race.
b. Using a brass bar and hammer, remove the oil storage ring and front bearing outer race.
20. Remove ring gear.
a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver and hammer, unstake the 5 lock plates.
c. Remove the 10 bolts and 5 lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
21. Check differential case runout.
a. Place the bearing outer races on their respective bearings. Check that the left and right outer races are not interchanged.
b. Install the assembled plate washers onto the side bearing.
c. Install the differential case in the differential carrier.
HINT: If it is difficult to install the differential case into the carrier, replace the plate washer with a thinner one. However, select a plate washer that allows no clearance between it and the carrier.
d. Align matchmarks on the bearing cap and differential carrier.
e. Install and uniformly tighten the 4 bolts a little at a time.
f. Using a dial indicator, measure the differential case run out.
Maximum case runout: 0.07 mm (0.0028 inch)
If the runout is greater than the maximum, replace the differential case and side bearings as a set.
g. Remove the differential case.
22. Remove side bearings.
Using SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04060, 09957-04010, 0995004010), 09950-60010 (09951 -00480), remove the 2 side bearings from the differential case.
HINT: Fix the claws of SST to the notches in the differential case.
23. Disassemble differential case assembly.
a. Using a pin punch and hammer, remove the straight pin.
b. Remove the pinion shaft, 2 pinion gears, pinion gear thrust washers, side gears and side gear thrust washers from the differential case.
COMPANION FLANGE REPLACEMENT
Replace companion flange dust deflector.
a. Using SST 09950-00020, 09950-60010 (09951-00400), 09950-70010 (09951-07100) and a press, remove the dust deflector.
b. Using SST 09223-00010 and a press, install a new dust deflector.
REASSEMBLY
HINT:
- Using a shop rag, clean off any foreign object from the parts.
- Apply all of the sliding and rotating surfaces with hypoid gear oil.
1. Measure side gear backlash and assemble differential case.
a. Install the 2 thrust washers to the 2 side gears.
b. Install the 2 side gears, pinion gears, pinion gear thrust washers and pinion shaft in the differential case.
HINT: Align the holes of the differential case and pinion shaft.
c. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.
Maximum backlash: 0.15 mm (0.0059 inch)
If the backlash is not within the specification, install side gear thrust washers with different thicknesses.
Thrust washer thickness.
Thickness mm (inch)
- 1.50 (0.0591), 1.55 (0.0610), 1.60 (0.0630), 1.65 (0.0650), 1.70 (0.0669), 1.75 (0.0689), 1.80 (0.0709), 1.85 (0.0729), 1.90 (0.0748)
2. Install straight pin and stake differential case.
a. Using a pin punch and hammer, install the straight pin through the differential case and hole of the pinion shaft.
b. Using a chisel and hammer, stake the outside of the differential case pin hole.
3. Install ring gear on differential case.
a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear to approx. 100°C (212°F) in boiling water.
c. Carefully take the ring gear out of the boiling water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
HINT: Align the matchmarks on the ring gear and differential case.
e. Temporarily install 5 new lock plates and 10 bolts so that the bolt holes in the ring gear and differential case are not misaligned.
f. After the ring gear has cooled sufficiently, torque the 10 ring gear set bolts.
Torque: 97 Nm (71 ft. lbs.)
g. Using a chisel and hammer, stake the 5 lock plates.
HINT: Stake the claws of the lock plates to fix the bolts. For the claw contacting the protruding portion of the bolt, stake only the half of it along the tightening direction.
4. Install side bearings.
Using SST 09315-00022 and a press, install the 2 bearings to the differential case.
5. Check ring gear runout.
a. Place the bearing outer races on their respective bearings. Check that the left and right outer races are not interchanged.
b. Install the assembled plate washers onto the side bearing.
c. Install the differential case in the differential carrier.
HINT: If it is difficult to install the differential case into the carrier, replace the plate washer with a thinner one. However, select a plate washer that allows no clearance between it and the carrier.
d. Align matchmarks on the bearing cap and differential carrier.
e. Install and uniformly tighten the 4 bolts a little at a time.
f. Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.07 mm (0.0028 inch)
g. Remove the differential carrier.
6. Install drive pinion front and rear bearing outer races.
a. Using SST 09950-60020 (09951-00780), 09950-70010 (09951-07150) and a press, install the front bearing outer race.
b. Using SST 09950-60020 (09951-00710), 09951-70010 (09951-07150) and a press, install the rear bearing outer race.
7. Install drive pinion front bearing.
a. Install the washer on the drive pinion.
HINT: First fit a washer with the same thickness as the washer which was removed, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.
b. Using SST 09506-30012 and a press, install the front bearing onto the drive pinion.
8. Temporarily adjust drive pinion preload.
a. Install the drive pinion and rear bearing.
HINT: Assemble the spacer and oil seal after adjusting the gear contact pattern.
b. Install the oil slinger.
c. Using SST 09950-30010, (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020), install the companion flange.
d. Using SST to hold the flange and adjust the drive pinion preload by tightening the nut.
NOTICE:
- Coat the nut and threads of the drive pinion with gear oil.
- As there is no spacer, tighten the nut a little at a time, being careful not to overtighten.
e. Using a torque wrench, measure the preload.
Preload (at starting):
- New bearing 1.0-1.6 Nm (8.7-13.9 inch lbs.)
- Reused bearing 0.5-0.8 Nm (4.3-6.9 inch lbs.)
HINT: Measure the total preload after turning the bearing clockwise and counterclockwise several times to make the bearing smooth.
9. Install differential case in differential carrier.
a. Place the bearing outer races on their respective bearings. Check that the left and right outer races are not interchanged.
b. Install the differential case in the differential carrier.
10. Adjust ring gear backlash.
a. Install the plate washer on the ring gear back side.
HINT: Make sure that the ring gear has backlash.
b. Tap on the ring gear with a plastic hammer so that the washer fits to the bearing.
c. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.
Backlash (Reference): 0.13 mm (0.0051 inch)
d. Select a plate washer for back side ring gear, using the backlash as reference.
Side plate washer thickness
Thickness mm (inch)
- 2.58 (0.1016), 3.04 (0.1197), 2.60 (0.1024), 3.06 (0.1205), 2.62 (0.1031), 3.08 (0.1213), 2.64 (0.1039), 3 10 (0.1220), 2.66 (0.1047), 3.12 (0.1228), 2.68 (0.1055), 3.14 (0.1236), 2.70 (0.1063), 3.16 (0.1244), 2.72 (0.1071), 3.18 (0.1252), 2.74 (0.1079), 3.20 (0.1260), 2.76 (0.1087), 3.22 (0.1268), 2.78 (0.1094), 3.24 (0.1276), 2.80 (0.1102), 3.26 (0.1283), 2.82 (0.1110), 3.28 (0.1291), 2.84 (0.1118), 3.30 (0.1299), 2.86 (0.1126), 3.32 (0.1307), 2.88 (0.1134), 3.34 (0.1315), 2.90 (0.1142), 3.36 (0.1323), 2.92 (0.1150), 3.38 (0.1331), 2.94 (0.1157), 3.40 (0.1339), 2.96 (0.1165), 3.42 (0.1346), 2.98 (0.1173), 3.44 (0.1354), 3.00 (0.1181), 3.46 (0.1362), 3 02 (0.1189), 3.48 (0.1370)
e. Select a ring gear teeth side plate washer so that is no clearance between the outer race and case.
f. Remove the plate washers and differential case.
g. Install the plate washer into the ring gear back side of the carrier.
h. Place the other plate washer onto the differential case together with the outer race, and install the differential case with the outer race into the carrier.
i. Tap on the ring gear with a plastic hammer so that the washers fit to the bearing.
j. Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13-0.18 mm (0.0051-0.0070 inch)
If the backlash is not within the specification, adjust by either increasing or decreasing the thickness of washers on both sides by an equal amount.
HINT: There should be no clearance between the plate washer and case. Make sure that there is ring gear backlash.
11. Adjust side bearing preload.
a. Remove the ring gear teeth side plate washer and measure the thickness.
b. Using the backlash as a reference, install a new washer of 0.06-0.09 mm (0.0024-0.0035 inch) thicker than the washer removed.
HINT: Select a washer which can be pressed in 2/3 of the way with your finger.
c. Using a plastic hammer, install the plate washer.
d. Align matchmarks on the bearing cap and differential carrier.
e. Tighten the 4 bolts.
Torque: 85 Nm (63 ft. lbs.)
f. Using a dial indicator, adjust the ring gear backlash until it is within the specification.
Backlash: 0.13-0.18 mm (0.0051-0.0070 inch)
If the backlash is not within the specification, adjust by either increasing or decreasing the thickness of washers on both sides by an equal amount.
HINT: The backlash will change by about 0.02 mm (0.0008 inch) corresponding to 0.03 mm (0.0012 inch) change in the plate washer.
12. Measure total preload.
Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus 0.4-0.6 Nm (3.5-5.2 inch lbs.)
13. Inspect tooth contact between ring gear and drive pinion.
a. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.
b. Hold the companion flange firmly and rotate the ring gear in both directions.
c. Inspect the tooth contact pattern.
If the teeth are not contacting properly, use the following table to select a proper washer for correction.
Washer thickness
Thickness mm (inch)
- 1.70 (0.0669), 2.03 (0.0799), 1.73 (0.0681), 2.06 (0.0811), 1.76 (0.0693), 2.09 (0.0822), 1.79 (0.0704), 2.12 (0.0835), 1.82 (0.0717), 2.15 (0.0847), 1.85 (0.0729), 2.18 (0.0858), 1.88 (0.0740), 2.21 (0.0870), 1.91 (0.0752), 2.24 (0.0882), 1.94 (0.0764), 2.27 (0.0894), 1.97 (0.0776), 2.30 (0.0906), 2.00 (0.0787), 2.33 (0.0918)
14. Remove companion flange.
15. Remove oil slinger.
16. Remove rear bearing.
17. Remove rear bearing outer race.
18. Install bearing spacer and oil storage ring.
a. Install a new bearing spacer.
b. Using SST 09316-60011 (09316-00011), 09506-35010 and a hammer, install a new oil storage ring.
19. Install rear bearing outer race.
Using SST 09316-60011 (09316-0011), 09506-35010 and a hammer, install the bearing outer race.
20. Install rear bearing and oil slinger.
21. Install oil seal.
a. Coat the hypoid gear oil to a new oil seal periphery.
b. Using SST 09554-30011 and a hammer, install a new oil seal.
Oil seal drive in depth: 1.5 mm (0.059 inch)
c. Coat MP grease to the oil seal lip.
22. Install companion flange.
a. Using SST 09950-30010 (09951-03010, 09953-03010, 09954 03010, 0995~03030, 09956-03020), install the companion flange.
b. Coat the thread of a new nut with hypoid gear oil LSD.
c. Using SST 09330-00021 to hold the flange, tighten the nut.
Torque: 108 Nm (80 ft. lbs.)
23. Adjust drive pinion preload.
Using a torque wrench, measure the drive pinion preload using the backlash of the drive pinion and ring gear.
Preload (at starting):
- New bearing: 1.0-1.6 Nm (8.7-13.9 inch lbs.)
- Reused bearing: 0.5-0.8 Nm (4.3-6.9 inch lbs.)
If the preload is greater than the specification, replace the bearing spacer.
If the preload is less than the specification, retighten the nut a force of 13 Nm (130 kgs.cm, 9 ft. lbs.) at a time until the specified preload is reached.
Torque: 338 Nm (249 ft. lbs.) or less
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not loosen the pinion nut to reduce the preload.
24. Recheck total preload.
25. Recheck ring gear backlash.
26. Recheck tooth contact between ring gear and drive pinion.
27. Check runout of companion flange.
28. Stake drive pinion nut.
29. Install side gear bearing.
Using SST 09502-12010, 09950 60020 (09951-0730), 09950-70010 (09951-07100) and a press, install the bearing to side gear shaft.
30. Install differential tube assembly.
a. Clean surfaces with FIPG material attached to using gasoline or alcohol.
b. Apply FIPG to the differential tube. FIPG: THREE BOND 1281 or equivalent.
HINT: Install the differential tube within 10 minutes after applying FIPG.
c. Install the differential tube with 4 bolts to the differential tube.
Torque: 105 Nm (77 ft. lbs.)
d. Install the side gear shaft.
e. Using a snap ring expander, install the snap ring.
f. Using SST 09350-30020 (09350-07060), install the snap ring.
31. Install side gear shaft oil seals.
a. Coat the hypoid gear oil to a new oil seal periphery.
b. Using SST 09550-00032, 09950-70010 (09951 -07150) and a hammer, install 2 new oil seals.
c. Coat MP grease to the oil seal lip.
32. Remove differential carrier from overhaul stand etc.
33. Install differential carrier cover.
a. Install the oil deflector with 2 bolts to the carrier cover.
Torque: 7.3 Nm (64 inch lbs.)
b. Install the breather plug to the carrier cover.
c. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and carrier cover.
d. Clean surfaces with FIPG with material attached to using gasoline or alcohol.
e. Apply FIPG to the carrier cover, as shown.
FIPG: THREE BOND 1281 or equivalent.
HINT: Install the carrier cover within 10 minutes after applying FIPG.
f. Install the differential carrier cover with the 9 bolts.
Torque: 47 Nm (34 ft. lbs.)