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. If necessary, observe the following.
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 0.05 mm (0.0020 inch).
If the backlash is not within the specification, adjust the backlash.
6. MEASURE DRIVE PINION PRELOAD
Using SST 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 (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
HINT: For vehicles that have run less than 8,000 km (5,000 miles), the preload may be large.
SST 09229-55010
Maximum preload (at starting): 1.8 Nm (18 kgf-cm, 15.6 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.
SST 09229-55010
Total preload (at starting):
Drive pinion preload plus 0.5 - 0.8 Nm (5 - 8 kgf-cm, 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.
9. CHECK TOOTH CONTACT PATTERN
Fig. 23 Removing Side Gear Shaft:
10. REMOVE SIDE GEAR SHAFTS
a. Using SST, remove the 2 side gear shafts.
SST 09520-24010
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, remove the 2 oil seals.
SST 09308-00010
12. REMOVE DIFFERENTIAL CARRIER RETAINERS
a. Remove the 16 bolts.
b. Using SST, remove the 2 carrier retainers and washers.
SST 09950-40011, (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00450)
13. REMOVE DIFFERENTIAL CASE
Take the differential case out of the carrier with lifting the ring gear side, as shown in the illustration.
NOTICE: Do not damage the side bearing.
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 and a press, remove the 2 outer races and adjusting plate washers.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
HINT:
^ Right and left adjusting plate should be clearly distinguished.
^ Measure the thickness and note down the measured value.
16. REMOVE DRIVE PINION, SPACER AND COMPANION FLANGE
a. Using a chisel and hammer, loosen the staked part of the nut.
b. Using SST, remove the nut.
SST 09229-55010, 09330-00021
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, remove the oil seal.
SST 09308-00010
18. REMOVE OIL SLINGER AND FRONT BEARING
19. REMOVE REAR BEARING FROM DRIVE PINION
Using SST and a press, remove the rear bearing from the drive pinion.
SST 09950-00020
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, remove the 2 side bearings from the differential case.
SST 09950-40011, (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00450)
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 the pinion shaft, 2 pinion gears, pinion gear thrust washers, side gears and side gear thrust washers from the differential case.
REPLACEMENT
1. REPLACE COMPANION FLANGE DUST DEFLECTOR
a. Using SST and a press, remove the dust deflector.
SST 09950-00020, 09950-60010 (09951-00510)
Fig. 30 Installing Companion Flange Dust Deflector:
b. Using SST and a press, install a new dust deflector.
SST 09316-60011 (09316-00011)
2. REPLACE SIDE GEAR SHAFT DUST COVER
a. Using SST and a press, remove the dust cover.
SST 09950-00020
Fig. 32 Installing New Side Gear Shaft Dust Cover:
b. Using SST and a press, install a new dust cover.
SST 09502-24010, 09950~0020 (09951-00780), 09950-70010 (09951-07150)
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: Using the table, select thrust washers that will ensure that the backlash is within the specification.
Thrust washer thickness:
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 (650 kgf-cm, 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 and a press, install the 2 side bearings.
SST 09710-30050, 09950-60010 (09951-00450), 09950-70010 (09951-07150)
6. INSTALL DRIVE PINION BEARING OUTER RACES AND ADJUSTING PLATE 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 and a press, install the front bearing outer race.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
b. Using SST and a press, install a new adjusting washer to the rear bearing outer race.
SST 09255-10012, 09950-70010 (09951-07150)
Fig. 35 Installing Rear Bearing To Drive Pinion:
7. INSTALL REAR BEARING TO DRIVE PINION
Using SST and a press, install the rear bearing.
SST 09502-24010
8. TEMPORARILY INSTALL DRIVE PINION, FRONT BEARING, OIL SLINGER AND COMPANION FLANGE
a. Install the drive pinion in the differential carrier.
b. Using SST and a press, install the front bearing on the drive pinion.
SST 09316-60011 (09316-00011), 09608-04031
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 and a press, install the companion flange.
SST 09223-06011, 09325-00010
9. TEMPORARILY ADJUST DRIVE PINION PRELOAD
a. Adjust the drive pinion preload by tightening the companion flange nut.
HINT: Using SST to hold the flange, tighten the nut.
SST 09229-55010, 09330-00021
NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.
b. Using SST and a torque wrench, measure the preload.
SST 09229-55010
Preload (at starting):
New bearing: 1.5 - 1.8 Nm (15 - 18 kgf-cm, 13.0 - 15.6 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (5 - 8 kgf-cm, 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 and a press, install the 2 adjusting plate washers and outer races.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07150)
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.
NOTICE: Do not damage the side bearing.
12. INSTALL DIFFERENTIAL CARRIER RETAINERS
a. Using SST and a hammer, install 2 carrier retainers.
SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)
b. Tighten the 16 bolts.
Torque: 22 Nm (225 kgf-cm, 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 within the specification replace the washer on the ring gear side with one of a different thickness using the following procedure.
Adjusting washer thickness
14. MEASURE TOTAL PRELOAD
Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
SST 09229-55010
Total preload (at starting):
Drive pinion pre-read plus 0.5 - 0.8 Nm (5 - 8 kgf-cm, 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 washer thickness by 0.02 mm (0.0008 inch) will change the total preload by approximately 0.1 Nm (1 kgf-cm, 0.9 inch lbs.)
15. INSPECT TOOTH CONTACT 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.
Fig. 17 Proper Contact Pattern:
c. Inspect the tooth 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.
HINT: Refer to the table on the next page for selection of the adjusting washer.
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
21. INSTALL OIL SLINGER
22. INSTALL OIL SEAL
a. Apply MP grease to a new oil seal lip.
b. Using SST, install the oil seal until its end is flush with the surface of the differential carrier.
SST 09316-60011 (09316-00011, 09316-00041), 09502-12010
Fig. 14 Pinion Flange Installation:
23. INSTALL COMPANION FLANGE
Using SST and a press, install the companion flange.
SST 09223-56010, 09325-40010
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 LSD.
b. Using SST, tighten the nut.
SST 09229-55010, 09330-00021
c. Using SST and a torque wrench, measure the preload.
SST 09229-55010
Preload (at starting):
New bearing: 1.5 - 1.8 Nm (15 - 18 kgf-cm, 13.0 - 15.6 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (5 - 8 kgf-cm, 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 (130 kgf-cm, 9 ft. lbs.) at a time until the specified preload is reached.
Torque: 490 Nm (5,000 kgf-cm, 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
27. INSTALL O-RING TO 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 and a press, install 2 new oil seals to the carrier retainers.
SST 09608-32010, 09950-70010 (09950-07150)
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 FIPG material using cleaner.
b. Coat FIPG to the carrier or cover.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
HINT: FIPG should be applied 2 to 3 mm in diameter with no brake.
^ Allow on overlap of 10 mm (0.37 inch) or more between the start and end of FIPG application.
^ Install the carrier cover within 3 minutes after applying FIPG.
c. Install the carrier cover to the carrier with the 8 bolts.
Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.)
HINT: Do not add oil or drive the vehicle immediately after installing the cover, and leave it as it is an hour or more.
Also, for 12 hours or more, avoid rapid acceleration/deceleration.
d. Install the breather plug.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)