Disassembly and Assembly

DISASSEMBLY
1. Remove differential carrier cover.
a. Remove the 8 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.

2. Set differential carrier to overhaul stand etc., as shown.

3. Check runout of drive pinion shaft.
Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 inch) away from the end of the shaft.
Maximum runout: 0.08 mm (0.0031 inch)
If the runout is greater than the maximum, replace the drive pinion and ring gear.

4. 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 drive pinion, ring gear and differential case.
5. Check ring gear backlash.

Using a dial indicator, measure the backlash of the ring gear at 3 points at least and check that the average value is within the specification.
Backlash: 0.08 - 0.13 mm (0.0031 - 0.0051 inch)

NOTICE: The difference between the maximum and minimum measured values must be less than 0.05mm (0.0020 inch).

If the backlash is not within the specification, adjust the backlash.

a. Adjust differential pinion gear backlash.
1. Install the 2 proper thrust-washers on the side gears

HINT: Select thrust washers which will ensure that the backlash is within the specification.

Thrust washer thickness: 1.50 mm (0.059 inch), 1.55 mm (0.061 inch), 1.60 mm (0.063 inch), 1.65 mm (0.065 inch), 1.70 mm (0.067 inch), 1.75 mm (0.069 inch), 1.80 mm (0.071 inch), 1.85 mm (0.073 inch), 1.90 mm (0.075 inch)

2. 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.

3. Push the 2 side gear shafts gently into the differential case by hand and install them.

4. Using a dial indicator, measure the pinion gear backlash with holding one side gear toward the case.
Maximum: 0.15 mm (0.0059 inch)

NOTICE: Differential gears should be able to rotate.

If the backlash is not within the specification, install the 2 side gear thrust washers with different thicknesses.

5. Remove the 2 side gear shafts.

6. Measure drive pinion preload.
Using Special Service Tool (SST) 09229-55010 or equivalent, and a torque wrench, measure the 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.)

HINT: For vehicles which have run less than 8,000 km (5,000 miles), the preload may be large.

Maximum preload (at starting): 1.8 Nm (16.0 inch lbs.)
7. Check total preload.
Using SST and 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: 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.)
If necessary, disassemble and inspect the differential.

8. Check pinion gear backlash.
Using a dial indicator, measure the pinion gear backlash with holding one side gear toward the case.
Maximum: 0.15 mm (0.0059 inch)

NOTICE: Differential gears should be able to rotate.

If the backlash is not within the specification, install the correct thrust washer. (See step 5)
9. Check tooth contact pattern.

a. Inspect tooth recontact pattern.
1. Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead.
2. Hold the companion flange firmly and rotate the ring gear in both directions.
3. Inspect the tooth contact pattern.

Fig. 17 Proper Contact Pattern:

If tooth contact pattern is not correct, replace the adjusting washer installed on the front of the drive pinion rear bearing to adjust it.

NOTICE: Make sure to always use a new one when replacing adjusting washer.

Fig. 23 Removing Side Gear Shaft:

10. Remove side gear shafts.
a. Using SST 09520-24010, remove the 2 side gear shafts.

NOTICE: Be careful not to damage the oil seal.

b. Using screwdriver, remove the 2 snap rings from the side gear shafts.

Fig. 24 Removing Side Gear Shaft Oil Seals:

11. Remove side gear shaft oil-seals using SST 09308-00010, remove the 2 oil seals.
12. Remove differential carrier-retainers.
a. Remove-the 16 bolts.

b. Using SST 09950-40010, (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04060, 09957-04010, 09958-04010), 09950-60010 (09951-00450), remove the 2 carrier retainers and washers.

13. Remove differential case.
Take the differential case out of the carrier with lifting the ring gear side, as shown in the illustration.
14. Remove O-rings from differential carrier retainers.
Using a screwdriver, remove the 2 O-rings.

Fig. 26 Removing Side Bearing Outer Race & Plate Washer:

15. Remove side bearing outer races and adjusting plate washers.
Using SST 09950-60020 (09951-00710), 09950-70010 (09951-07150) and a press, remove the 2 outer races and adjusting plate washers.
16. Remove drive pinion, spacer and companion flange.
a. Using a chisel and hammer, loosen the staked part of the nut.

b. Using SST 09229-55010, 09330-00021, remove the nut.

c. Using a press, remove the drive pinion with the rear bearing and remove the companion flange.

NOTICE: Be careful not to drop the drive pinion.

d. Remove the spacer from the drive pinion.

Fig. 27 Removing Pinion Oil Seal:

17. Remove oil seal.
Using SST 09308-00010, remove the oil seal.
18. Remove oil slinger and front bearing.

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

20. Remove front and rear bearing outer races and adjusting plate washer.

NOTICE: Do not remove the outer race except when replacing the bearings.

HINT: Measure the washer and note the thickness for reassembly.

21. Remove side bearings.
Using SST 09950-40010, (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04060, 09957-04010, 09958-04010), 09950-60010 (09951-00450), remove the 2 side bearings from the differential case.

22. Remove ring gear.
a. Place matchmarks on the ring gear and differential case.
b. Remove the 10 ring gear set bolts.
c. Using a plastic hammer, tap on the ring gear to separate it from the differential case.

23. Disassemble differential case.
a. Using a pin punch and hammer, remove the straight pin.
b. Remove these parts from the differential case:
- Pinion shaft
- 2 pinion nears
- 2 pinion gear thrust washers
- 2 side gears
- 2 side gear thrust washers

REPLACEMENT
1. Replace companion flange must deflector.

a. Using SST 09950-00020, 09950-60010 (09951-00510) and a press, remove the dust deflector.

Fig. 30 Installing Companion Flange Dust Deflector:

b. Using SST 09316-60011 (09316-00011) and a press, install a new dust deflector.
2. Replace side gear shaft dust cover.

a. Using SST 09950-00020 and a press, remove the dust cover.

Fig. 32 Installing New Side Gear Shaft Dust Cover:

b. Using SST 09502-24010, 09950-60020 (09951-00780), 09950-70010 (09951-07150) and a press, install a new dust cover.

HINT: If the dust cover does not fit snugly against the flange of the side gear shaft, use a screwdriver to drive it down.

REASSEMBLY
1. Adjust differential pinion gear backlash.

a. Install the 2 proper thrust-washers on the side gears

HINT: Select thrust washers which will ensure that the backlash is within the specification.

Thrust washer thickness: 1.50 mm (0.059 inch), 1.55 mm (0.061 inch), 1.60 mm (0.063 inch), 1.65 mm (0.065 inch), 1.70 mm (0.067 inch), 1.75 mm (0.069 inch), 1.80 mm (0.071 inch), 1.85 mm (0.073 inch), 1.90 mm (0.075 inch)

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. Push the 2 side gear shafts gently into the differential case by hand and install them.

d. Using a dial indicator, measure the pinion gear backlash with holding one side gear toward the case.
Maximum: 0.15 mm (0.0059 inch)

NOTICE: Differential gears should be able to rotate.

If the backlash is not within the specification, install the 2 side gear thrust washers with different thicknesses.

e. Remove the 2 side gear shafts.

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. Stake the differential case.
3. Install ring gear on differential case.
a. Clean the contact surfaces of the differential case and the threads of the ring gear and differential case.

b. Heat the ring gear in boiling water.
c. Carefully remove the ring gear from 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 the differential case.

e. Tighten 2 of the bolts temporarily so that the bolt holes in the ring gear and differential case are not misaligned.

NOTICE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently.

4. Install ring gear set bolts.

a. After the ring gear has cooled sufficiently, install new 10 ring gear set bolts to which thread lock has been applied.
Thread lock: Part No. 08833-00100, THREE BOND 1360 K or equivalent.

NOTICE: New ring gear set bolts should be used in every case.

b. Torque the 10 set bolts uniformly and a little at a time.
Torque: 64 Nm (47 ft. lbs.)
c. Tighten the bolts further by 60-90°.

NOTICE: Tighten the bolts in diagonally opposite pairs.

5. Install side bearings
Using SST 09710-30050, 09950-60010 (09951-00450), 09950-70010 (09951-07150) and a press, install the 2 side bearings.
6. Install drive pinion bearing outer races and adjusting washer.

HINT:
- The adjusting washer is used for adjusting the tooth contact pattern. 42 types of washer with different thicknesses are available.
- 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.
- When removing an adjusting washer, be sure to replace it with a new one.

a. Using SST 09950-60020 (09951-00710), 09950-70010 (09951-07150) and a press, install the front bearing outer race.
b. Using SST 09250-10011 (09255-10011), 09950-70010 (09951-07150) and a press, install a new adjusting washer to the rear bearing outer race.

Fig. 35 Installing Rear Bearing To Drive Pinion:

7. Install rear bearing to drive pinion.
Using SST 09502-24010 and a press, install the rear bearing.
8. Temporarily install drive pinion, front bearing, oil slinger and companion flange.
a. Install the drive pinion in the differential carrier.

b. Using SST 09316-60011 (09316-00011), 0960-04031 and a press, install the front bearing on the drive pinion.

HINT: Assemble the spacer and oil seal after adjusting the tooth contact pattern.

c. Install the oil slinger.

Fig. 14 Pinion Flange Installation:

d. Using SST 09223-46011, 09325-40010 and a press, install the companion flange.
9. Temporarily adjust drive pinion preload.
a. Adjust the drive pinion preload by tightening the companion flange nut.

HINT: Using SST 09229-55010, 09330-00021 to hold the flange, tighten the nut.

NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.

b. Using SST 09229-55010 and a torque wrench, measure the preload.
Preload (at starting):
New bearing: 1.5 - 1.8 Nm (13.0 - 15.6 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.)

HINT: For vehicles which have run 8,000 km (5,000 miles) or less, if the preload value measured before disassembly is greater than the specification for a reused bearing, return the preload to the same as before disassembly.

Fig. 36 Installing Side Bearing Outer Race & Adjusting Washer:

10. Install side bearing outer races and adjusting plate washers.
Using SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) and a press, install the 2 adjusting plate washers and outer races.

11. Install differential case in carrier.
Install the drive side bearing in the differential carrier first, as shown in the illustration, then install the differential case.

12. Install differential carrier retainers.
a. Using SST 09950-60020 (09951-00890), 09950-70010 (09951-07150) and a hammer, install 2 carrier retainers.
b. Tighten the 16 bolts.
Torque: 22 Nm (16 ft. lbs.)

13. Check ring gear backlash.
Using a dial indicator, measure the backlash of the ring gear at 3 positions at least.
Backlash: 0.08 - 0.13 mm (0.0031 - 0.0051 inch)

NOTICE: The difference between the maximum and minimum measure values must be less than 0.05 mm (0.0020 inch).

HINT: The measured values should be used as reference when selecting washers, so take a note of the values.

If the backlash is not fitting the specific at or replace the washer on the ring gear side wish one of a different thickness using the following procedure.

Adjust washer thickness

14. Measure total preload.
Using SST 09229-55010 and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preread (at starting):
Drive pinion preload plus 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.)
If the measured preload is less than the specification, replace the washer of the ring gear's tooth surface side with a thicker one.
If the preload is greater than the specification, replace the washer of the ring gear's tooth surface side with a thinner one.

HINT: Changing the snap ring thickness by 0.02 mm (0.0008 inch) will change the total preload by approx. 0.1 Nm (0.9 inch lbs.).

15. Inspect tooth recontact pattern.

a. Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead.
b. Hold the companion flange firmly and rotate the ring gear in both directions.
c. Inspect the tooth contact pattern.

Fig. 17 Proper Contact Pattern:

HINT: Adjust washers in 42 (different thickness in 0.01 mm (0.004 inch)) units are available.

16. Remove differential carrier retainers.
17. Remove differential case.
18. Remove drive pinion.
19. Install spacer on drive pinion.
Install a new spacer on the drive pinion.
20. Install drive pinion and front bearing. (See step 8)
21. Install oil slinger. (See step 8)
22. Install oil seal.
a. Apply Multipurpose (MP) grease to a new oil seal lip.

b. Using SST 09316-60011 (09316-00011,09316-00041) 09502-12010, install the oil seal until its end is flush with the surface of the differential carrier.

Fig. 14 Pinion Flange Installation:

23. Install companion flange.
Using SST 09223-56010, 09325-40010 and a press, install the companion flange.

NOTICE: Be careful not to damage the oil seal.

24. Adjust drive pinion preload.
a. Coat the threads and flange of a new nut with hypoid gear oil for Limited Slip Differential (LSD).

b. Using SST 09229-55010, 09330-00021 tighten the nut.

c. Using SST 09229-55010 and a torque wrench, measure the preload.
Preload (at starting):
New bearing: 1.5 - 1.8 Nm (13.0 - 15.6 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 spacer.
If the preload is less than the specification, retighten the nut with a force of 13 Nm (9 ft. lbs.) at a time until the specified preload is reached.
Torque: 490 Nm (362 ft. lbs.) or less
If the maximum torque is exceeded while retightening the nut, replace the spacer and repeat the preload procedure.
Do not back off the nut to reduce the preload.
25. Check runout of drive pinion shaft.
26. Install differential case in-carrier. (See step 11)

27. Install O-ring from differential carrier retainers
a. Coat 2 new O-rings with hypoid gear oil.
b. Install the 2 O-rings to the carrier retainers.

Fig. 26 Removing Side Bearing Outer Race & Plate Washer:

28. Install oil seals from differential carrier retainers.
a. Using SST 09608-32010, 09950-70010 (09950-07150) and a press, install 2 new oil seals to the carrier retainers.
b. Coat the MP grease to the oil seal lip.
29. Install differential carrier retainers.
30. Recheck backlash, total preload and tooth contact pattern.

31. Stake drive pinion nut.
32. Install snap rings to side gear shafts.
a. Install 2 new snap rings to the side gear shafts.
b. Coat the MP grease to the snap rings.

33. Install side gear shafts.
Using a brass, and hammer, install the 2 side gear shafts.

HINT: Whether or not the side gear shaft is making contact with the pinion shaft can be known by the sound or feeling when driving it in.

NOTICE: Be careful not to damage the oil seal.

34. Remove differential carrier from overhaul stand, etc.

35. Install differential carrier cover.
a. Clean the contact surfaces of the carrier and cover of any residual Formed In Place Gasket (FIPG) material using cleaner.
b. Coat FIPG to the carrier or cover.
FIPG: THREE BOND 1281 or equivalent.
c. Install the carrier cover to the carrier with the 8 bolts.
Torque: 47 Nm (34 ft. lbs.)
d. Install the breather plug.
Torque: 21 Nm (15 ft. lbs.)