Less Differential Lock and Limited Slip

DISASSEMBLY

1. Set differential carrier to overhaul stand etc.





2. Check runout of companion flange.
Using a dial indicator, measure the vertical and lateral runout of the companion flange.
Maximum runout: 0.10 mm (0.0039 inch)
If the runout is not within the specification, replace the companion flange.





3. Check ring gear runout.
Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 inch)
If the runout is greater than the maximum, replace the ring gear.





4. Check ring gear backlash.
Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13-0.18 mm (0.0051-0.0071 inch)

HINT:
- Perform the measurements at 3 or more positions around the circumference of the ring gear.
- If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.





5. Measure drive pinion preload.
Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.
Preload (at starting): 0.64-0.92 Nm (5.6-8.2 inch lbs.)
6. Check total preload.
Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
- Drive pinion preload plus 0.38-0.63 Nm (3.4-5.6 inch lbs.)
If necessary, disassemble and inspect the differential.
7. Check tooth contact between ring gear and drive pinion.
8. Remove companion flange.
a. Using a chisel and hammer, unstake the nut.





b. Using Special Service Tool (SST) 09330-00021 or equivalent, to hold the flange, remove the nut.





c. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040), remove the companion flange.





9. Remove oil seal and oil slinger.
a. Using SST 09300-10010, remove the oil seal from the differential carrier.
b. Remove the oil slinger.





10. Remove front bearing.
Using SST 09556-22010, remove the front bearing from the drive pinion.
If the front bearing is damaged or worn, replace the bearing.





11. Remove differential case assembly.
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 2 bolts and 2 adjusting nut locks.
c. Remove the 4 bolts, 2 bearing caps and 2 adjusting nuts.

HINT: Tag the disassembled parts to show the location for reassembly.

d. Remove the differential case with the bearing outer races from the carrier.

HINT: Tag the disassembled parts to show the location for reassembly.

12. Remove drive pinion and bearing spacer from differential carrier.
a. Remove the drive pinion with the rear bearing.
b. Remove the bearing spacer.





13. Remove drive pinion rear bearing.
a. Using SST 09950-00020 and a press, remove the rear bearing from the drive pinion.

HINT: If the drive pinion or ring gear is damaged, replace them as a set.

b. Remove the plate washer from the drive pinion.





14. Remove front and rear bearing outer races.
Using a brass bar and hammer, remove the outer races.





15. Remove ring gear.
a. Place matchmarks on the ring gear and differential case.
b. Remove the 12 ring gear set bolts.
c. Using a plastic hammer, tap on the ring gear to remove it from the differential case.
16. 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 differential case in the differential carrier.
c. Tighten the adjusting nut just to where there is no play in the bearing.
d. Align matchmarks on the bearing cap and differential carrier.
e. Install and uniformly tighten the 4 bearing cap bolts a little at a time.





f. Using a dial indicator, measure the differential case runout.
Maximum case runout: 0.04 mm (0.0016 inch)
If the runout is greater than the maximum, replace the differential case and side bearings as a set.
g. Remove the differential case.





17. Remove side bearings from differential case.
Using SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-0010 (09951-00480), remove the 2 side bearings from the differential case.





18. Disassemble differential case.
a. Place matchmarks on the LH and RH differential cases.
b. Remove the 8 bolts uniformly, a little at a time.
c. Using a plastic hammer, separate the LH and RH differential cases.
d. Remove the 2 side gear thrust washers, 2 side gears, spider, 4 pinion gears and 4 pinion gear thrust washers.

COMPANION FLANGE REPLACEMENT





1. Remove companion flange dust deflector.
Using SST 09950-00020 a steel plate and press, remove the dust deflector.





2. Install dust deflector.
Using SST 09726-40010 a steel plate and 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.
a. Install the 2 thrust washers to the side gears.
b. Install the side gear assembly to the differential case.
c. Install the 4 pinion gears and thrust washers to the spider.
d. Install the spider assembly to the differential case.

HINT: Install the spider to the differential case tightly.






e. Using a dial indicator, measure the side gear backlash with the side gear and spider.
Backlash: 0.02-0.15 mm (0.0008-0.0059 inch)

HINT:
- Measure at all 4 locations.
- Measure the backlash at the LH and RH differential cases.

If the backlash is not within the specification, install a thrust washer of a different thickness.
Thrust washer thickness
Thickness mm (inch)
- 1.55 (0.0610), 1.85 (0.0728), 1.60 (0.0630), 1.90 (0.0748), 1.65 (0.0650), 1.95 (0.0768), 1.70 (0.0669), 2.00 (0.0787), 1.75 (0.0689), 2.05 (0.0807), 1.80 (0.0709), 2.10 (0.0827)
2. Assemble differential case.
a. Reinstall the spider assembly to the differential case.

HINT: Install the spider to the differential case tightly.






b. Align the matchmarks and assemble the LH and RH differential cases.
c. Tighten the 8 bolts uniformly, a little at a time.
Torque: 47 Nm (35 ft. lbs.)





3. Install side bearing.
a. Using SST 09710-30050, 09950-70010 (09951-07100) and a press, install the RH side bearing on the differential case.





b. Using SST 09710-30050, 09950 60010 (09951~0480), 09950-70010 (09951-07100) and a press, install the LH side bearing on the differential case.
4. Install ring gear on differential case.
a. Clean the threads of the bolts and differential case with the white gasoline.
b. Clean the contact surfaces of the differential case and ring gear.





c. Heat the ring gear to about 100°C (212°F) in boiling water.
d. Carefully take the ring gear out of the boiling water.
e. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.





f. Align the matchmarks on the ring gear and differential case.
g. Temporarily install the 12 set bolts.
h. After the ring gear cools down enough, torque the 12 set bolts to which thread lock has been applied.
Thread lock: THREE BOND 1360 K or equivalent
Torque: 137 Nm (101 ft. lbs.)
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 differential case onto the carrier and tighten the adjusting nut just to where there is no play in the bearings.





c. Using a dial indicator, check the ring gear runout.
Maximum runout: 0.05 mm (0.0020 inch)
d. Remove the differential case.





6. Install front and rear bearing outer races.
a. Using SST 09950-0020 (09951-00710), 09950-70010 (09951-07150) and a press, install the front bearing outer race.
b. Using SST 09950-0020 (09951-00890), 09950-70010 (09951-07150) and a press, install the rear bearing outer race.
7. Install drive pinion rear 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, re place the washer with one of a different thickness if necessary.






b. Using SST 0950-35010 and a press, install the rear bearing onto the drive pinion.
8. Temporarily adjust drive pinion preload.
a. Install the drive pinion and front 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, 09956-03040), install the companion flange.





d. Using SST 09330-00021 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 1.3- 1.8 Nm (11.3- 16.4 inch lbs.)
- Reused bearing 0.64-0.92 Nm (5.6-8.2 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 carrier.
a. Place the 2 bearing outer races on their respective bearings. Make sure that the left and right outer races are not interchanged.
b. Install the differential case in the carrier.

HINT: Make sure that there is backlash between the ring gear and drive pinion.






10. Install adjusting nuts.
Install the 2 adjusting nuts on the carrier, making sure the nuts are engaged properly.





11. Install bearing caps.
Align the matchmarks on the bearing cap and carrier. Screw in the 2 bearing cap bolts 2 or 3 turns and press down the bearing cap by hand.

HINT: If the bearing cap does not fit tightly on the carrier, the adjust nuts are not engaged properly.

Reinstall the adjusting nuts if necessary.





12. Adjust side bearing preload.
a. Torque the 4 bolts.
Torque: 83 Nm (61 ft. lbs.)





b. Then loosen them to the point where the adjusting nuts can be turned by SST 09504-00011.
c. Fully tighten the 4 bolts by hand.
d. Using SST, torque the adjusting nut on the ring gear side until the ring gear has a backlash of about 0.2 mm (0.008 inch).





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





f. Place a dial indicator on the top of the adjusting nut on the ring gear side.
g. Adjust the side bearing to zero preload by tightening the other adjusting nut until the pointer on the indicator begins to move.





h. Using SST, torque the adjusting nut 1 -1.5 notches from the zero preload position.





i. Using a dial indicator, adjust the ring gear backlash until it is within the specification.
Backlash: 0.13-0.18 mm (0.0051-0.0071 inch)

HINT: The backlash is adjusted by turning the left and right adjusting nuts by equal amount. For example, loosen the nut on the left side 1 notch and torque the nut on the right side 1 notch.






j. Torque the 4 bearing cap bolts.
Torque: 83 Nm (61 ft. lbs.)
k. After rotating the ring gear 5 turns or more, recheck the ring gear backlash.
Backlash: 0.13-0.18 mm (0.0051-0.0071 inch)





13. Measure total preload.
Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Preload (at starting):
- Drive pinion preload plus 0.38-0.63 Nm (3.4-5.6 inch lbs.)





14. 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. Turn the companion flange, in both directions to inspect the ring gear for proper tooth contact.





If the teeth are not contacting properly, use the following chart to select a proper washer for correction.
Thickness mm (inch)
- 1.050 (0.04134), 1.325 (0.05217), 1.075 (0.04232), 1.350 (0.05315), 1.100 (0.04331), 1.375 (0.05413), 1.125 (0.04429), 1.400 (0.05512), 1.150 (0.04528), 1.425 (0.05610), 1.175 (0.04626), 1.450 (0.05709), 1.200 (0.04724), 1.475 (0.05807), 1.225 (0.04823), 1.500 (0.05906), 1.250 (0.04921), 1.525 (0.06004), 1.275 (0.05020), 1.550 (0.06102), 1.300 (0.05118)
15. Remove companion flange.
16. Remove oil slinger and front bearing.





17. Remove bearing outer race.
Using SST 0930-00010, remove the bearing outer race.
18. Install new bearing spacer.





19. Install bearing outer race.
Using SST 0931-60011 (09316-00011, 09316-00021) and a hammer, install the bearing outer race.
20. Install front bearing and oil slinger.
21. Install oil seal.
a. Coat the hypoid gear oil to a new oil seal periphery.





b. Using SST 09214-76011 and a hammer, install a new oil seal.
Oil seal drive in depth: 0.5 mm (0.020 inch)
c. Coat the MP grease to the oil seal lip.





22. Install companion flange.
a. Using SST 09950-30010 (09951-3010, 09953-03010, 09954-03010, 0995-03030, 09956-03040), install the companion flange.
b. Coat the threads of a new nut with hypoid gear oil LSD.





c. Using SST 09330-0021 to hold the flange, tighten the nut.
Torque: 245 Nm (181 ft. lbs.)





23. Adjust drive pinion preload.
Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting):
- New bearing 1.3-1.8 Nm (11.3-16.4 inch lbs.)
- Reused bearing 0.64-0.92 Nm (5.6-8.2 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 with a force of 13 Nm (130 kgs.cm, 9 ft. lbs.) at a time until the specified preload is reached.
Torque: 441 Nm (326 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 ring gear backlash.
25. Recheck tooth contact between ring gear and drive pinion.
26. Check runout of companion flange.
27. Stake drive pinion nut.





28. Install adjusting nut locks.
a. Install 2 new nut locks on the bearing caps.
b. Tightening 2 bolts, bend the nut locks.
Torque: 13 Nm (9 ft. lbs.)
29. Remove differential carrier from over haul stand etc.