Assembly

1. Press in the new differential mounting rubber, with the voids facing fore and aft, with SST #49 N034 213 or equivalent. Press to 19600N (4400 lbf).
2. Install the breather and baffle.






3. Apply lithium based grease to the new oil seal lip and install it with SST #49 B001 795 or equivalent.
4. Install rear bearing inner race.






5. Install the front bearing outer race with SST #49 G030797 and #49 H033 101.






6. Install the rear bearing outer race with SST #49 G030 797 and #49 F027 005.






7. Using the Special Service Tools shown above, adjust the drive pinion height as follows.






8. Install the spacer that was removed and the rear bearing inner race onto SST #49 8531 565 as shown.






9. Assemble the same spacer that was removed during disassembly and assemble the spacer, rear bearing inner race and SST as shown.
10. Secure the SST with the O-ring, then install this assembly in the carrier.
11. Install the front bearing inner race, the SST, the companion flange, washer, and the same nut that was removed during disassembly.
12. Tighten the nut just enough so that the companion flange can still be turned by hand.






13. Place SST #49 0727 570 on the surface plate and set the dial indicator to "Zero".






14. Place the SST atop the drive pinion model. Set the gauge body atop the gauge block.
15. Place the feeler of the dial indicator so that it contacts where the side bearing inner race is installed in the carrier.
16. Measure the lowest possible position on the left and right sides of the carrier.






17. Add the two (left and right) values obtained in Step 17 and divide the total by 2. Specification is 0mm (0 in.).






18. If not within specification, adjust the pinion height by selection of a spacer. Select the spacer thickness that is closest to that necessary.






19. Install the spacer selected being careful that the installation direction is correct. Press in until the force required suddenly increases.
20. Press the rear bearing inner race on with the SST.






21. Install the drive pinion, spacer, new collapsible spacer, front bearing, washer, and companion flange to the carrier and temporarily tighten the locknut with the spanner wrench. Do not install the oil seal at this time. Torque to 128 Nm (94 ft.lbs).
22. Turn the companion flange several turns by hand to seat the bearing.






23. Measure the drive pinion preload by tightening the locknut and record the tightening torque. Preload: 0.9 - 1.3 kgf cm (7.9 - 12.1 in.lbs). Tightening torque: 128 - 284 Nm (94.1 - 209.7 ft.lbs).
24. Remove the locknut, washer, and companion flange.






25. Tap a new oil seal into the differential carrier with SST #49 J027 003 as shown.






26. Apply a light coat of grease to the end face of the companion flange.






27. Install the companion flange and washer. While holding the flange with the spanner wrench, torque the new locknut to 128 - 284 Nm (94 - 209.7 ft.lbs).






28. Set a dial gauge against the pinion gear as shown. Secure on of the side gears.
29. Move the pinion gear and measure the backlash at the end of it. Should not exceed 0 - 0.1mm (0 - 0.0039 in).






30. If the backlash exceeds the standard, use the selectable thrust washers for adjustment.






31. Install a new knock pin to secure the pinion shaft. Stake the pin with a punch to prevent it from coming out of the case.






32. Apply thread-locking compound (approx. 0.04cc (0.0024 cu in.) at each point) to the bolt threads (A) and point (B) of the gear back face.
33. Install the ring gear onto the gear case. Torque mount bolts to 69 - 83 Nm (51 - 61 ft.lbs).







34. Using SST #49 G030 338, press the side bearing inner races on, then install the differential gear assembly in the carrier.
35. Note the identification marks on the adjusting nuts and install them on their respective sides.






36. Install the differential bearing caps, making sure that the identification mark on the cap corresponds with the one the carrier using SST #49 0259 720 as shown.






37. Mark the ring gear at four points at approx. 90° intervals. Mount a dial indicator to the carrier so that the feeler comes in contact at a right angle with one of the ring gear teeth.
38. Turn both bearing adjusters equally with SST #49 0259 720 until the backlash is 0.09 - 0.11mm (0.0035 - 0.043 in).






39. Check the backlash at the three other marked points, make sure the maximum backlash is less than 0.07mm (0.0028 in).

Note: When adjusting the differential bearing preload, be careful not to affect the backlash of the drive pinion and ring gear.






40. Tighten the adjusting nuts equally until the distance between the pilot sections on the bearing caps is 185.428 - 185.50mm (7.3003 - 7.3031 in).






41. Coat both surfaces of 6 - 8 teeth of the ring gear with a thin coat of red lead.
42. while moving the ring gear back and forth by hand, rotate the drive pinion several times and check the tooth contact.






43. If the tooth contact is good, wipe off the read lead.
44. If the lead shows toe and flank contact replace the spacer with a thinner one to move the drive pinion outward.






45. If the lead shows heel and face contact, replace the spacer with a thicker one to bring the drive pinion in.






46. Torque the bearing cap bolts to 37 - 51 Nm 28 - 38 ft.lbs).






47. Install the lock plates on the bearing caps and torque to 18 - 25 Nm (14 - 18 ft.lbs).






48. Apply sealant to the housing face and install, torque mount bolts to 23 - 26 Nm (17 - 19 ft.lbs).






49. Install a new clip then install the output shafts into the side gears by lightly tapping them with a plastic hammer.

Caution: On LSD units, the right output shaft is longer than the left shaft.

50. Verify that the output shafts are hooked into the side gears by pulling them by hand.