Part 2

41. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
(a) Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03060)





42. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST remove the oil seal from the differential carrier.
SST 09308-10010
43. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Using a magnet hand, remove the differential drive pinion oil slinger.





44. REMOVE DIFFERENTIAL DRIVE PINION
(a) Using a press, remove the drive pinion with the rear bearing from the differential carrier.

NOTICE: Be careful not to drop the drive pinion.





45. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Remove the spacer from the drive pinion.

46. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING





(a) Remove the front bearing from the differential carrier.





(b) Using a brass bar and a hammer, remove the front bearing outer race.

47. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING





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





(b) Using a brass bar and a hammer; remove the rear bearing outer race.
(c) Remove the plate washer.

48. REMOVE DIFFERENTIAL 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.

49. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSY





(a) 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 case bearing.





(b) Using SST and a hammer, install the outer race on the drive pinion side.
SST 09608-32010, 09950-70010 (09951-07200)

HINT: Tap in the outer race until half on the side gear shaft shaft snap ring groove of the differential carrier can be seen.





(c) Place the SST on the differential carrier.
SST 09571-50010
(d) Tighten the SST bolt until the SST disc lightly touches the case bearing (outer race).





(e) Using SST and a hammer, install the outer race on the ring gear side.
SST 09950-70010 (09951-07200), 09608-32010

HINT: Tap in the outer race until it touches the case bearing roller.

(f) Place a dial indicator on the differential case flange surface at a right angle.





(g) Using a dial indicator, measure the differential case run- out.
Maximum runout: 0.05 mm (0.0020 in.)
If the runout is greater than the maximum, replace the rear differential case sub-assy with a new one.





50. REMOVE REAR DIFFERENTIAL CASE BEARING
(a) Tighten the SST bolt to push out the ring gear side outer race.
SST 09571-50010

NOTICE: Do not drop the side bearing (outer race).

(b) Remove the SST





51. REMOVE REAR DIFFERENTIAL CASE BEARING
(a) Raise the ring gear side of the differential case slightly to remove the drive pinion side outer race.





52. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY

NOTICE: Do not damage the side bearing.





53. REMOVE REAR DIFFERENTIAL CASE BEARING
(a) Using SST, remove the 2 differential case bearings from the differential case.
SST 09950-60010 (09951-00480), 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)

NOTICE: Do not deform the bearing case.

Hook the claws of the SST to the bearing inner race from the differential case.





54. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
(a) Using SST and a press, remove the dust deflector.
SST 09950-60010 (09951-00440), 09950-00020, 09950-70010 (09951-07100)





55. INSPECT DIFFERENTIAL PINION GEAR BACKLASH
(a) Using a vise, hold the differential case between two aluminium plates.
(b) Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0 mm (0 in.).
If the backlash is not within the specification, replace the rear differential case sub-assy with a new one.





56. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
(a) Perform this procedure only when replacing the dust cover.
(b) Using SST and a press, insert a new dust deflector into the companion flange.
SST 09316-60011 (09316-00011)

NOTICE:
- Slowly press a new dust deflector into the companion flange while observing the dust deflector. Do not press excessively.
- If necessary, remove any burrs after inserting the new dust deflector.

57. INSTALL DIFFERENTIAL RING GEAR
(a) Clean the contact surfaces of the differential case and the threads of the ring gear and differential case.





(b) Heat the ring gear to approximately 100°C (212°F) 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 match marks on the ring gear and the differential case.

(e) Tighten the new 2 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 been cooled sufficiently.

58. INSTALL REAR DIFFERENTIAL CASE BOLT
(a) Clean the differential ring gear set bolt hole.





(b) After the ring gear has been cooled sufficiently, install the new 8 ring gear set bolts to which thread lock has been applied.
Thread lock: Part No.08833-00100, THREE BOND 1360K or equivalent.

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





(c) Torque the 10 set bolts uniformly and a little at a time.
Torque: 64 Nm (650 kgf-cm, 47 ft-lbf)
(d) Tighten the bolts further by 60 to 90°.

NOTICE: Tighten the bolts in diagonally opposite pairs.





59. INSTALL REAR DIFFERENTIAL CASE BEARING
(a) Using SST and a press, install the 2 differential case bearings.
SST 09950-60010 (09951-00560), 09950-70010 (09951-07100), 09950-60020 (09951-00810), 09950-70010 (09951-07100)

NOTICE:
- Align the SST with the center of the differential case.
- Replace the bearing outer race when bearing is replaced.
- The ring gear tooth (90366-50087) and back surfaces (90366-50027) have different bearing. Because of this, install the ring gear paying attention to their part numbers.

60. INSTALL REAR DIFFERENTIAL CASE BEARING





(a) Using SST and a press, install the rear bearing.
SST 09502-24010





(b) Using SST and a press, install the rear bearing outer race and adjusting washer.
SST 09950-70010 (09951-07100), 09255-10012

HINT: Select a thrust shim of the same thickness as the removed one.

61. INSTALL DIFFERENTIAL DRIVE PINION





(a) Using SST and a press, install the front bearing outer race.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07100)
(b) Install the drive pinion in the differential carrier.





(c) Using SST and a press, install the front bearing on the drive pinion.
SST 09316-60011 (09316-00011), 09608-04031 (09951-07200)

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

62. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD





(a) Using SST install the companion flange onto the differential carrier.
SST 09950-30012 (09951-03010, 09954-03010, 09956-03060, 09955-03040)

NOTICE: Because the spacer is not installed, maintain a little looseness between the companion flange and the drive pinion when installing.





(b) Adjust the drive pinion preload by tightening the companion flange nut.

HINT: Tighten the nut using approximately 98 Nm (1,000 kgf-cm, 72 ft lbf) of force and then tighten it further while observing the preload.

(1) Using SST to hold the flange, tighten the nut.
SST 09229-55010, 09330-00021





(c) Using SST and a torque wrench, measure the preload.
Preload (at starting):
New bearing:
1.5 to 2.0 Nm (15 to 21 kgf-cm, 13.0 to 17.8 in.-lbf)
Reused bearing:
0.5 to 0.8 Nm (5 to 8 kgf-cm, 4.3 to 6.9 in.-lbf)

HINT:
- Do not apply hypoid gear oil if a new bearing is used.
- Turn the bearing clockwise and counterclockwise several times to stabilize the bearing, and then measure the backlash.
- If the preload is not within the specification, adjust the rear differential drive pinion preload or repair as necessary.





63. INSTALL REAR DIFFERENTIAL CASE SUB-ASSY
(a) 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 case bearing and ring gear.

64. INSTALL REAR DIFFERENTIAL CASE BEARING





(a) Using SST and a hammer; install the drive pinion side outer race.
SST 09608-32010, 09950-70010 (09951-07200)

HINT: Tap in the outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.





(b) Place the SST to the differential carrier.
SST 09571-50010
(c) Tighten the SST bolt until the SST disc lightly touches to the case bearing (outer race).





(d) Using SST and a hammer, install the ring gear side outer race.
SST 09950-70010 (09951-07200), 09608-32010

HINT: Tap in the outer race until it touches the case bearing roller.

65. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING

HINT: This procedure is required only when final gear set (drive pinion & ring gear) is replaced.





(a) Using snap ring pliers, install the thinnest side gear shaft shaft snap ring on the ring gear side.





(b) Install a dial indicator to the differential carrier.
(c) Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).
SST 09571-50010

NOTICE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

HINT:
- Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side gear shaft oil seal is tapped in.
- Tighten the SST bolt to apply the preload to the case bearing.

(d) Turn the ring gear clockwise and counterclockwise several times.





(e) Using a dial indicator, measure the backlash of the ring gear at 3 positions.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE: The difference between the maximum and minimum values must be within 0.05 mm (0.002 in.).

HINT: Write the values for reference to select a side gear shaft shaft snap ring. If a value is not within the specified range, replace it with one of a different thickness in the following procedure.

(f) Loosen the SST bolt and separate the SST disc from the case bearing (outer race) on the drive pinion.





(g) Using SST and a hammer, create a clearance between the side gear shaft shaft snap ring on the ring gear side and outer race.
SST 09608-32010, 09950-70010 (09951-07200)





(h) Using snap ring pliers, remove the side gear shaft shaft snap ring on the ring gear side.





(i) Using snap ring pliers, install a side gear shaft shaft snap ring with different thickness.





HINT:
- There are 39 different thicknesses of the side gear shaft shaft snap ring available in 0.02 mm (0.008 in.) difference.
- When the side gear shaft shaft snap ring thickness changes by 0.02 mm (0.008 in.), the backlash changes by 0.02 mm (0.008 in.).





(j) Using a plastic hammer, lightly tap the drive pinion side of the differential carrier.





(k) Install a dial indicator onto the differential carrier.
(l) Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).
SST 09571-50010

HINT: Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal tapped in.





(m) Using a dial indicator, measure the ring gear backlash.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
(n) If the backlash is not within the specified range, replace the side gear shaft shaft snap ring on the ring gear side with one of a different thickness.

66. ADJUST DIFFERENTIAL RING GEAR BACKLASH





(a) Install a dial indicator to the differential carrier.
(b) Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in).
SST 09571-50010

HINT: Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal tapped in.





(c) Using snap ring pliers, install the thinnest side gear shaft shaft snap ring on the drive pinion side.
(d) Remove the dial indicator and loosen the bolt until the SST disc is separated from the outer race.





(e) Using a plastic hammer, lightly tap the drive pinion side of the differential carrier.





(f) Check the backlash around the ring gear. If even one backlash is smaller than the specified value, adjust the differential ring gear backlash by replacing the side gear shaft shaft snap ring on the drive pinion side with a thicker one.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)

HINT: If a value is not within the specified range, replace it with one of a different thickness in the following procedure.

(g) Loosen the SST bolt and separate the SST disc from the case bearing (outer race) on the drive pinion.





(h) Using SST and a hammer, create a clearance between the side gear shaft shaft snap ring on the ring gear side and outer race.
SST 09608-32010, 09950-70010 (09951-07200)





(i) Using snap ring pliers, remove the side gear shaft shaft snap ring on the ring gear side.





(j) Using snap ring pliers, install a side gear shaft shaft snap ring with different thickness.





HINT:
- There are 39 different thicknesses of the side gear shaft shaft snap ring available in 0.02 mm (0.008 in.) difference.
- When the side gear shaft shaft snap ring thickness changes by 0.02 mm (0.008 in.), the backlash changes by 0.02 mm (0.008 in.).





(k) Using a plastic hammer, lightly tap the drive pinion side of the differential carrier.





(l) Check the backlash around the ring gear. If even one backlash is smaller than the specified value, adjust the differential ring gear backlash by replacing the side gear shaft shaft snap ring on the drive pinion side with a thicker one.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)

HINT: If a value is not within the specified range, replace it with one of a different thickness in the same procedure.

67. ADJUST TOTAL PRELOAD





(a) 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 0.46 to 1.37 Nm (4.69 to 13.97 kgf-cm, 4.07 to 12.13 in.-lbf)

NOTICE:
- If the measured preload is less than the specification, replace the rear differential side gear shaft shaft snap ring of the ring gear's tooth surface side with a thicker one.

If the preload is greater than the specification, replace the rear differential side gear shaft shaft snap ring of the ring gear's tooth surface side with a thinner one.

HINT: When the rear differential side gear shaft shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the total preload will change by approximately 0.1 Nm (1 kgf-cm, 0.9 in.-lbf).





(b) Set a dial indicator to the end of the differential ring gear face.
(c) While holding the rear drive pinion companion flange rear, rotate the differential ring gear and measure the backlash.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE:
- If the measured value is out of the specified value, adjust it by increasing or decreasing the thickness of both right and left side gear shaft shaft snap ring equally.
- When the side gear shaft shaft snap ring thickness changes by 0.02 mm (0.008 in.), the backlash will change by approximately 0.02 mm (0.008 in.).

(d) Recheck the total preload.

68. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Coat 3 or 4 teeth at the 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 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 replace the adjusting washer with a new one.








HINT: There are 42 thicknesses of the rear differential drive pinion plate washers available in 0.01 mm (0.04 in.) difference.

69. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING





(a) Install the SST to the rear differential carrier assy.
SST 09571-50010





(b) Install a dial indicator to the rear differential carrier assy.
(c) Tighten the SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.004 in.) clearance between the side bearing (outer race) and side gear shaft snap ring.

NOTICE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

HINT:
- Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal tapped in.
- Approximately 0.1 mm (0.004 in.) clearance between the side bearing (outer race) and the side gear shaft shaft snap ring is sufficient enough for the washer to move slightly.





(d) Using snap ring pliers, remove the side gear shaft shaft snap ring on the drive pinion side.

HINT: For reassembly purposes, measure the thickness of the side gear shaft shaft snap ring. Write down the result.

(e) Remove the dial indicator and loosen the SST bolt.

NOTICE: Do not remove the SST.