Overhaul (Unit Overhaul)

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 the carrier.
c. Remove the breather plug from the differential carrier cover.
d. Remove the bolt and oil deflector from the differential carrier cover.
2. REMOVE DIFFERENTIAL CARRIER STRAIGHT PIN
Using pliers, remove the straight pin from the differential carrier.
3. SET DIFFERENTIAL CARRIER TO OVERHAUL STAND, ETC.





4. CHECK COMPANION FLANGE RUNOUT
Using a dial indicator, measure the vertical and lateral runout of the companion flange.
Maximum runout: 0.09 mm (0.0035 inch)
If the runout is greater than the maximum, replace the companion flange.





5. CHECK RING GEAR RUNOUT
Using a dial indicator, while turning the companion flange 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.





6. CHECK RING GEAR BACKLASH
Using a dial indicator, while holding the companion 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 specified value, adjust the backlash.





7. 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): 0.49 - 0.78 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)





8. REMOVE SIDE GEAR SHAFTS
a. Using SST and 2 bolts, remove the 2 side gear shafts from the differential carrier.
SST 09520-24010
b. Using a screwdriver, remove the 2 snap rings from the side gear shafts.
9. CHECK TOTAL PRELOAD
Using a torque wrench, measure the total preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus 0.39 - 0.59 Nm (4 - 6 kgf-cm, 3.5 - 5.2 inch lbs.)
If necessary, disassemble and inspect the differential.
10. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION





11. 2 pinion differential:
CHECK SIDE GEAR BACKLASH
Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specified value, install the correct thrust washers.





12. REMOVE SIDE GEAR SHAFT OIL SEALS
Using SST, remove the 2 side gear shaft oil seals.
SST 09308-00010
13. REMOVE COMPANION FLANGE
a. Using a chisel and hammer, unstake the nut.





b. Using SST to hold the flange, remove the nut.
SST 09330-00021





c. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)





14. REMOVE FRONT OIL SEAL AND OIL SLINGER
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
b. Remove the oil slinger.





15. REMOVE FRONT BEARING
Using SST, remove the front bearing from the drive pinion.
SST 09556-22010
If the front bearing is damaged or worn, replace the front 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 and a plastic hammer, remove the 2 plate washers.
SST 09504-22012

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

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

b. Remove the washer.





19. REMOVE FRONT AND REAR BEARING OUTER RACES
Using a brass bar and hammer, remove the front and rear bearing outer races.





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 around on the ring gear equally 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 right and left outer races are not interchanged.
b. Install the assembled plate washers onto the side bearings.
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, while turning the companion flange measure the differential case runout.
Maximum 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





a. 2 pinion differential:
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 (09951-00480)

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

b. Torque sensing LSD ring gear side:
Using SST, remove the side bearing from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00480)

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





c. Torque sensing LSD ring gear back side:
Using SST, remove the side bearing from the differential case.
SST 09950-00020, 09950-40011 (09951-04020, 09953-04030, 09957-04010), 09950-50012 (09952-05010, 09954-05030, 09955-05040)
23. 2 pinion differential:
DISASSEMBLE DIFFERENTIAL CASE ASSEMBLY





NOTICE: If equipped with torque sensing LSD, do not disassemble the differential case.





a. Using a pin punch (5 mm) 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, IF NECESSARY





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





b. Using SST and a press, install a new dust deflector.

NOTICE: SST 09710-04061

Do not deform the dust deflector.
2. REPLACE SIDE GEAR SHAFT DUST COVER, IF NECESSARY





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, 09950-60020 (09951-00780), 09950-70010 (09950-07150)

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. 2 pinion differential:
MEASURE SIDE GEAR BACKLASH AND REASSEMBLE 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.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specified value, install the side gear thrust washers with different thicknesses.





Thrust washer thickness:





2. 2 pinion differential:
INSTALL STRAIGHT PIN AND STAKE DIFFERENTIAL CASE
a. Using a 5 mm 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 (985 kgf-cm, 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 and a press, install the 2 bearings to the differential case.
SST 09710-04081, 09950-60010 (09951-00600), 09950-70010 (09951-07100)
5. CHECK RING GEAR RUNOUT
a. Place the bearing outer races on their respective bearings. Check that the right and left outer races are not interchanged.
b. Install the assembled plate washers onto the side bearings.
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 case.





6. INSTALL FRONT AND REAR BEARING OUTER RACES
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 the rear bearing outer race.
SST 09950-60020 (09951-00790), 09950-70010 (09951-07200)
7. INSTALL 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 and a press, install the rear bearing onto the drive pinion.
SST 09506-30012
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, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)





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 hypoid gear oil LSD.
^ 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 drive pinion preload using the backlash between the drive pinion and ring gear.
Preload (at starting):
New bearing: 0.98 - 1.57 Nm (10 - 16 kgf-cm, 8.7 - 13.9 inch lbs.)
Reused bearing: 0.49 - 0.78 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)

HINT: Measure the drive pinion 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 right and left 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, while holding the companion flange, measure the ring gear backlash.
Backlash (Reference): 0.13 - 0.18 mm (0.0051 - 0.0071 inch)





d. Select a plate washer for backside ring gear, using the backlash as reference.





Side plate washer thickness:





e. Select a ring gear teeth side plate washer so that there 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, while holding the companion flange measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
If the backlash is not within the specified value, 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.

Make sure that there is ring gear backlash.
11. ADJUST SIDE BEARING PRELOAD





a. Remove the ring gear teeth side plate washer and using a micrometer, measure the thickness.
b. Using the backlash as a reference, install a new washer 0.06 - 0.09 mm (0.0024 - 0.0035 inch) thicker than the washer removed.

HINT: Select a washer that 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 (870 kgf-cm, 63 ft. lbs.)





f. Using a dial indicator, while holding the companion flange adjust the ring gear backlash until it is within the specified value.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
If the backlash is not within the specified value, 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 with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus 0.39 - 0.59 Nm (4 - 6 kgf-cm, 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:

14. REMOVE COMPANION FLANGE
15. REMOVE OIL SLINGER
16. REMOVE FRONT BEARING
17. INSTALL BEARING SPACER
Install a new bearing spacer.

HINT: Face the spacer with the large inner diameter to the rear side.

18. INSTALL FRONT BEARING AND OIL SLINGER





19. INSTALL FRONT OIL SEAL
a. Using SST and a hammer, install a new oil seal.
SST 09554-30011
Oil seal drive in depth: 2.00 ± 0.45 mm (0.0787 ± 0.0177 inch)
b. Coat MP grease to the oil seal lip.
20. INSTALL COMPANION FLANGE





a. Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
b. Coat the thread of a new nut with hypoid gear oil LSD.





c. Using SST to hold the flange, tighten the nut.
SST 09330-00021
21. ADJUST DRIVE PINION PRELOAD





Using a torque wrench, measure the drive pinion preload using the backlash between the drive pinion and ring gear.
Preload (at starting):
New bearing: 0.98 - 1.57 Nm (10 - 16 kgf-cm, 8.7 - 13.9 inch lbs.)
Reused bearing: 0.49 - 0.78 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)





If the preload is greater than the specified value, replace the bearing spacer.
If the preload is less than the specified value, retighten the nut with a force of 13 Nm (130 kgf-cm, 9 ft. lbs.) at a time until the specified preload is reached.
SST 09330-00021
Torque: 338 Nm (3,443 kgf-cm, 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.
22. RECHECK TOTAL PRELOAD
23. RECHECK RING GEAR BACKLASH
24. RECHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
25. CHECK COMPANION FLANGE RUNOUT
26. STAKE DRIVE PINION NUT
Using a chisel and hammer, stake the nut.





27. INSTALL SIDE GEAR SHAFT OIL SEALS
a. Using SST and a press, install 2 new oil seals.
SST 09554-22010
Oil seal drive in depth: 0 ± 0.50 mm (0 ± 0.0197 inch)
b. Coat MP grease to the oil seal lip.
28. INSTALL SIDE GEAR SHAFTS
a. Using needle-nose pliers, install 2 new snap rings to the side gear shafts.
b. Coat the MP grease to the snap rings





c. Using SST and 2 bolts, install the side gear shaft to the differential carrier.
SST 09520-24010

NOTICE: Be careful not to damage the side gear shaft oil seal.

HINT:
^ Before installing the side gear shaft, set the snap ring with it's opening side facing downward.
^ Whether the side gear shaft is in contact with the side gear or not can be known from the sound or feeling when driving it.

d. Check that the side gear shaft will not come out by trying to pull it out by hand.
e. Employ the same manner described to the other side.
29. REMOVE DIFFERENTIAL CARRIER FROM OVERHAUL STAND, ETC.





30. INSPECT DIFFERENTIAL CARRIER
Using vernier calipers, measure the distance between the right and left side gear shafts, as shown in the illustration.
Standard distance: 279.7 mm (11.012 inch) or less
31. INSTALL DIFFERENTIAL CARRIER STRAIGHT PIN
Using a plastic hammer, install the straight pin.
32. INSTALL DIFFERENTIAL CARRIER COVER
a. Install the oil deflector with the bolt to the carrier cover.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
b. Install the breather plug to the carrier cover.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
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 both installation surfaces of loose FIPG and oil material with gasoline or alcohol.





e. Apply FIPG to the carrier cover, as shown in the illustration.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent.

HINT:
^ Allow an 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.

f. Install the differential carrier cover 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 for an hour or more.

Also, for 12 hours or more, avoid rapid acceleration/deceleration.