Part 3

OVERHAUL (CONTINUED)





61. INSTALL REAR DIFFERENTIAL CASE BOLT
a. Clean the differential ring gear set bolt hole.
b. Wait until the ring gear has cooled sufficiently.
c. Apply thread lock to 8 new ring gear set bolts.
Thread lock: Part No. 08833-00100, THREE BOND 1360 K or equivalent.

NOTICE: Always use new ring gear set bolts.

d. Install the 8 ring gear set bolts to the ring gear.





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

NOTICE: Tighten the bolts in diametrically opposite pairs.





62. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, press in the 2 differential case bearings.
SST 09950-60010 (09951-00560), 09950-60020 (09951-00810), 09950-70010 (09951-07100, 09951-07200)

NOTICE:
^ Align SST with the center of the differential case.
^ Replace the bearing outer race when bearing is replaced.
^ Be careful as the 2 bearings are different. The ring gear tooth side's bearing is part no. 90366-50087 and the other side's bearing is part no. 90366-50027.





63. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, press in the rear bearing.
SST 09502-24010





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

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





64. INSTALL DIFFERENTIAL DRIVE PINION
a. Using SST and a press, press in the front bearing outer race.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07200)
b. Install the drive pinion in the differential carrier.





c. Using SST and a press, press in the front bearing on the drive pinion.

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

SST 09316-60011 (09316-00011), 09608-04031





65. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Using SST, install the companion flange onto the differential carrier.
SST 09950-30012(09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060)

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. lbs.) of force. Then tighten it further while observing the preload.

1. Using SST to hold the flange, tighten the nut.
SST 09229-55010, 09550-30012 (09955-03040), 09330-00021 (09330-00030)





c. Using SST and a torque wrench, measure the preload.
SST 09229-55010





Preload (at starting)

HINT:
^ Do not apply hypoid gear oil if a new bearing is used.
^ If the preload is not within the specification, adjust the rear differential drive pinion preload or repair as necessary.

NOTICE: For a more accurate measurement, rotate the bearing forward and backward several times before measuring.





66. INSTALL REAR DIFFERENTIAL CASE SUB-ASSY
a. Insert the differential case from the ring gear tooth side to install.

NOTICE: Do not damage the case bearing and ring gear.





67. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a hammer, tap in 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. Install 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, tap in 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.





68. Ring gear side position:
REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

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

a. Using snap ring pliers, install the thinnest side gear 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 inch).
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 inch).

HINT:
^ Set the dial indicator to the rearmost position (upper side in the illustration) of the area where the side gear shaft oil seal is tapped inch)
^ 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.

HINT: Perform the measurements at the 3 or more positions around the side bearing preload.

Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)

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

HINT: Write the values for reference to select a side gear shaft snap ring. If a value is not within the specified range, replace it with one of a different thickness in the following procedure. 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 snap ring on the ring gear side and outer race.
SST 09608-32010, 09950-70010 (09951-07200)





h. Using snap ring pliers, remove the snap ring on the ring gear side.
i. Using snap ring pliers, install a snap ring with a different thickness.





HINT:
^ Side gear shaft snap rings are available in 39 sizes, each with a 0.02 mm (0.0008 inch) thickness difference.
^ When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 inch), the backlash changes by 0.02 mm (0.0008 inch).





j. Using a plastic-faced 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 inch).
SST 09571-50010

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





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





69. 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 inch).
SST 09571-50010

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





c. Using snap ring pliers, install the thinnest side gear 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-faced hammer, lightly tap the drive pinion side of the differential carrier.





f. Check the backlash around the ring gear.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)

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

If a value is not within the specified range, replace it with one of a different thickness (proceed to step g).
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 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 snap ring on the ring gear side.
j. Using snap ring pliers, install a side gear shaft snap ring with different thickness.





HINT:
^ Side gear shaft snap rings are available in 39 sizes, each with a 0.02 mm (0.0008 inch) thickness difference.
^ When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 inch), the backlash changes by 0.02 mm (0.0008 inch).





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





l. Check the backlash around the ring gear.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)

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

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





70. 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 inch lbs.)
If the measured preload is less than the specification, replace the rear differential side gear 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 snap ring of the ring gear's tooth surface side with a thinner one.

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





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 inch)
If the measured value is not as specified, adjust it by increasing or decreasing the thickness of the right and left side gear shaft snap ring equally.

NOTICE: When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 inch), the backlash will change by approximately 0.02 mm (0.0008 inch).
d. Recheck the total preload.
71. 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.

NOTICE: Make sure to always replace the adjusting washer with a new one.





HINT: Refer to the adjusting washer table.

d. Rear differential drive pinion plate washers are available in 42 sizes, each with a 0.01 mm (0.0004 inch) thickness difference.





72. Except ring gear side position: REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
a. Install SST to the rear differential carrier.
SST 09571-50010





b. Install a dial indicator to the rear differential carrier.
c. Tighten the SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.0004 inch) clearance between the side bearing (outer race) and snap ring.
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 (0.0008 inch).

HINT:
^ Set the dial indicator to the rearmost position (upper side in the illustration) of the area where the side oil seal tapped inch)
^ Approximately 0.1 mm (0.0004 inch) clearance between the side bearing (outer race) and the snap ring is sufficient for the washer to move slightly.





d. Using snap ring pliers, remove the snap ring on the drive pinion side.

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

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

NOTICE: Do not remove SST.





73. Ring gear side position: REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
a. Using SST and a hammer, create a clearance between the side bearing (outer) on the ring gear and snap ring.
SST 09608-32010, 09950-70010 (09951-07200)

HINT: The clearance cannot be seen, but tapping SST with a hammer three or four times should be enough.





b. Using snap ring pliers, remove the snap ring on the ring gear side.

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





74. Ring gear side position: REMOVE REAR DIFFERENTIAL CASE BEARING
a. Tighten the SST bolt and push out the outer race on the ring gear side.
SST 09571-50010

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

b. Remove SST.





75. Except ring gear side position: REMOVE REAR DIFFERENTIAL CASE BEARING
a. Raise the ring gear side of the differential case slightly to remove the drive pinion side outer race.

HINT: For reassembly, check the installation position of the outer race and of the side gear shaft snap ring before removing the outer race. Write down the result.





76. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY

NOTICE: Be careful not to damage the case bearing.





77. REMOVE REAR DRIVE PINION NUT
a. Using SST to hold the flange, remove the nut.
SST 09229-55010, 09330-00021 (09330-00030), 09950-30012 (09955-03040)





78. 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, 09956-03060, 09955-03040)
79. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Using a magnet hand, remove the differential drive pinion oil slinger.





80. REMOVE DIFFERENTIAL DRIVE PINION
a. Using a press, press out the drive pinion with the rear bearing from the differential carrier.

NOTICE: Be careful not to drop the drive pinion.





81. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Remove the front bearing from the differential carrier.





82. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install the spacer to the drive pinion.





83. INSTALL DIFFERENTIAL DRIVE PINION
a. Using SST and a press, press in the drive pinion (rear bearing rear inner race) and rear drive pinion tapered roller bearing front inner race to the differential carrier.
SST 09316-60011 (09316-00011), 09608-04031
84. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Install the rear differential drive pinion oil slinger to the differential drive pinion.





85. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
a. Apply a small amount of MP grease to a new oil seal lip.
b. Using SST and a hammer, tap the oil seal into the rear differential carrier.
SST 09316-60011 (09316-00011), 09710-04101

NOTICE: Be sure that the oil seal is straight during insertion.

Oil seal depth: 0 ± 0.5 mm (0 ± 0.020 inch)





86. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using SST, install the companion flange to the differential carrier.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060)
b. Apply hypoid gear oil LSD to the threads of a new nut.





c. Using SST, hold the flange and tighten the nut while observing the preload with SST and torque wrench.
SST 09229-55010, 09550-30012 (09955-03040), 09330-00021 (09330-00030)
Torque: 98 Nm to 490 Nm (1,000 to 5,000 kgf-cm, 72 to 361 ft. lbs.)

NOTICE:
^ Do not tighten excessively, otherwise the threads will be stripped.
^ Apply hypoid gear oil LSD to the threads of the nut and drive pinion.

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





87. INSTALL REAR DIFFERENTIAL CASE SUB-ASSY
a. Install the differential case from the ring gear tooth side to install.

NOTICE: Do not damage the case bearing or ring gear.





88. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a hammer, tap in 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. Install 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, tap in 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.





89. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
a. Using snap ring pliers, install the snap ring in the differential carrier on the ring gear side.

HINT: Use the side gear shaft snap ring installed when performing tooth contact adjustment.





b. Set a dial indicator on the differential carrier.
c. Tighten the SST bolt to alter the differential carrier's shape.
SST 09571-50010

NOTICE: Do not alter the shape excessively.

Shaped limit: 0.2 mm (0.008 inch)





d. Using snap ring pliers, install the side gear shaft snap ring on the drive pinion side.

HINT: Use the side gear shaft snap ring installed at tooth contact adjustment.





e. Remove the dial indicator, tap the differential carrier on the drive pinion side using a plastic-faced hammer to stabilize the case bearing.





90. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

NOTICE: Rotate the flange clockwise and counterclockwise several times to stabilize the bearing before measuring the differential drive pinion preload.

a. Using SST and a torque wrench, measure the preload.
SST 09229-55010





Preload (at starting)

If the preload is greater than the specified maximum value, re place the bearing spacer.

NOTICE: Because the bearing spacer deforms with use, replace the bearing spacer with a new one if the drive pinion preload is greater than the maximum value.

If the preload is less than the specified minimum value, check the preload while retightening the nut by 5 to 10 degrees to adjust it into the specified value range.
Torque: 98 to 490 Nm (1,000 to 5,000 kgf-cm, 72 to 361 ft. lbs.)

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

NOTICE: In some cases, the nut torque is greater than the specified value but the preload is still less than the specified minimum value. If so, proceed to step (d). If not, proceed to step 91.

b. Loosen the nut and check that the threads of the nut and drive pinion are not damaged.
If the threads are not stripped, replace the spacer and apply hypoid gear oil LSD to the threads. Then repeat step 90.