With Differential Lock

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 0.3-0.5 Nm (2.6-4.3 inch lbs.)
If necessary, disassemble and inspect the differential.
7. Check tooth contact between ring gear and drive pinion.
8. Remove rear diff. lock position switch.
Remove the rear diff. lock position switch and gasket.
9. Remove cover.
a. Remove the 3 bolts.
b. Using a brass bar and hammer, tap on the cover to remove it.





10. Remove actuator, shift fork and sleeve.
a. Remove the 4 bolts.





b. Remove the shift fork shaft bolt.
c. Using a screwdriver, pull out the actuator and remove the sleeve and shift fork.
11. 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.





12. Remove oil seal and oil slinger.
a. Using SST 0930010010, remove the oil seal from the differential carrier.
b. Remove the oil slinger.





13. 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.





14. 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 plate washers.

HINT: Measure the plate washer thickness and note down it.

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

HINT: Tag the bearing outer races to show the location for reassembly.

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





16. 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.





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





18. 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.
19. 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: 0.04 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.





20. Disassemble differential case.
a. Place matchmarks on the differential case and differential cover.
b. Using a torx socket (E10), remove the 5 set bolts and 3 pinion shaft pins.
c. Separate the cover and case. Remove the 2 side gears, side gear thrust washers, 4 pinion gears, 4 pinion gear thrust washers, 3 pinion shafts and holder from the differential case.





21. Remove side bearing from differential case.
Using SST 09950-40011 (09951-04010, 09952~4010, 09953-04020, 09955-04060, 09957-04010, 09958-04010), 09950-0010 (09951~0580), remove the side bearing.

HINT: Fix the claws of SST to the notches in the differential case






22. Remove side bearing from differential cover.
Using SST 09950-60010 (09951-00580), 09950-70010 (09951-07100), 4 bolts and a press, remove the side bearing.



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 2 side gears.
b. Install the 4 thrust washers to the 4 pinion gears.





c. Install the 2 side gears into the differential case.
d. Install the holder into the differential case.
e. Install the 4 pinion gears with the thrust washers.
f. Align the holes of the differential case and pinion shaft, and install the 3 pinion shafts.
g. Install the side gear to the differential cover.
h. Align the matchmarks and install the differential case and differential cover.
Using a torx socket (E10), install the 5 bolts and 3 pinion shaft pins.
Torque: 58 Nm (590 kgs.cm, 43 ft. lbs.)





j. Using a dial indicator, while holding the side gear measure the backlash.
Backlash: 0.02-0.15 mm (0.0008-0.0059 inch)
If the backlash is not within the specification, install the thrust washer of a different thickness.

HINT:
- Try to select washers of the same size for both sides.
- Measure at all 4 locations. 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)
k. After measuring backlash, remove the 5 set bolts and 3 pinion shaft pins.
2. Assemble differential case.
a. Clean the threads of the bolts, pinion shaft pins, case and cover with the white gasoline.





b. Coat the threads of the bolts and pinion shaft with adhesive.
Adhesive: THREE BOND 1324 or equivalent.
c. Align the matchmarks, install the case and cover.
d. Using a torx socket (E10), install the 5 bolts and 3 pinion shaft pins.
Torque: 58 Nm (43 ft. lbs.)





3. Install side bearings.
a. Differential cover side:
- Using SST 09550-60010 and a press, install the side bearing on the differential cover.





b. Ring gear side:
- Using SST 09550 60010 and a press, install the 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 on 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 has cooled down enough, torque the 12 set bolts to which thread lock has been applied.
Thread lock: THREE BOND 1360K 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 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, check the ring gear runout.
Maximum runout: 0.05 mm (0.0020 inch)
g. Remove the differential case.





6. Install drive pinion front and rear bearing outer races.
a. Using SST 09950-60020 (09951-00710), 09950-70010 (09951-07150) and a press, install the front bearing outer race.
b. Using SST 09950-60020 (09951 -00890), 09950-70010 (09951-071 50) 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, replace the washer with one of a different thickness if necessary.






b. Using SST 09506-35010 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, 0995003010, 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 races are not interchanged.
b. Install the assembled plate washer onto the side bearing.
c. Install the differential case in the carrier.





d. Settle down the plate washer and bearing snugly by tapping on the ring gear with a plastic hammer.

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.






10. Adjust ring gear backlash.
a. Using a dial indicator, while holding the side bearing of the ring gear side measure the backlash.
Backlash (Reference): 0.15 mm (0.0059 inch)
b. Select a case cover side plate washer using the backlash as a reference.





Side plate washer thickness





c. Select a ring gear teeth side plate washer so that there is no clearance between the outer race and case.





d. Remove the 2 plate washers and differential carrier.
e. Install the plate washer into the lower part of the carrier.
f. Place the plate washer onto the differential case together with the outer races, and install the differential case with the outer race into the carrier.
g. Settle down the plate washer and bearing snugly by tapping on the ring gear with a plastic hammer.





h. Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13-0.18 mm (0.0051-0.0071 inch)
If it is not within the specification, adjust it 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.

Ensure that there is ring gear backlash.
11. Adjust side bearing preload.
a. After adjustment using the backlash as reference, remove the ring gear side plate washer.





b. Using a micrometer, measure the thickness of the removed plate washer.
c. Install a new washer 0.06-0.09 mm (0.0024-0.0035 inch) thicker than the removed washer.

HINT: Select a washer which can be pressed in 2/3 of the way with finger.






d. Using SST 09504-22010, tap in the plate washer.
e. Align the matchmarks on the cap and carrier.
f. Tighten the 4 bearing cap bolts to the specified torque.
Torque: 113 Nm (83 ft. lbs.)





g. 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)
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.
h. After rotating the ring gear 5 turns or more, recheck the ring gear backlash.





12. 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 preread plus 0.3-0.5 Nm (2.6-4.3 inch lbs.)





13. Inspect tooth contact between ring gear.
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, 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)
14. Remove companion flange.
15. Remove oil slinger and front bearing.





16. Remove bearing outer race.
Using SST 09308-00010, remove the bearing outer race.

17. Install new bearing spacer.





18. Install bearing outer race.
Using SST 09316-60011 (09316-00011, 09316-00021) and a hammer, install the bearing outer race.
19. Install front bearing and oil slinger.
20. 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, as shown.
Oil seal drive in depth: 0.5 mm (0.020 inch)
c. Coat the MP grease to the oil seal lip.





21. Install companion flange.
a. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040), install the companion flange.
b. Coat the threads of a new nut with hypoid gear oil LSD.





c. Using SST 09330-00021 to hold the flange, tighten the nut.
Torque: 245 Nm (181 ft. lbs.)





22. 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.
23. Recheck ring gear backlash.
24. Recheck tooth contact between ring gear and drive pinion.
25. Check runout of companion flange.
26. Stake drive pinion nut.
27. Install actuator, shift fork and sleeve.
a. Clean contacting surfaces of any FIPG material using gasoline or alcohol.





b. Apply FIPG to the actuator.
FIPG: THREE BOND 1281 or equivalent

HINT: Install the actuator within 10 minutes after applying FIPG.






c. Install the shift fork and actuator to the differential and match the shift fork hole with the shift fork.
d. Clean the threads of the set bolt and fork shaft with the white gasoline.





e. Coat the threads of the set bolt with adhesive.
Adhesive: THREE BOND 1324 or equivalent
f. Tighten the shift fork shaft set bolt.
Torque: 20 Nm (14 ft. lbs.)





g. Engage the sleeve with the dog clutch of the differential case.





h. Tighten the 4 bolts.
Torque: 24 Nm (17 ft. lbs.)
28. Install cover.
a. Clean contacting surfaces of any FIPG material using gasoline or alcohol.





b. Apply FIPG to the cover.
FIPG: THREE BOND 1281 or equivalent

HINT: Install the cover within 10 minutes after applying FIPG.

c. Tighten the 3 bolts.
Torque: 18 Nm (13 ft. lbs.)
29. Install rear diff. lock position switch.
Install the rear diff. lock position switch with a new gasket.
Torque: 40 Nm (30 ft. lbs.)
30. Remove differential carrier from overhaul stand etc.