Disassembly and Assembly

DISASSEMBLY
Side Shaft





1. Drain gear oil, if necessary.
2. Remove side oil seal.

CAUTION: Be careful not to damage gear carrier.





3. Remove snap ring (hole side).





4. Remove side shaft assembly out of gear carrier.

NOTE: Tap on side shaft assembly from side gear side.

5. Remove snap ring (shaft side).





6. Press side shaft out of side shaft bearing.

CAUTION: Do not drop side shaft.

Differential Assembly
1. Remove side shaft assembly. Refer to "Side Shaft".
2. Remove rear cover mounting bolts.





3. Remove rear cover to insert seal cutter between gear carrier and rear cover.
Tool number: KV10111100 (J-37228)

CAUTION:
^ Be careful not to damage the mating surface.
^ Do not insert flat-bladed screwdriver, this will damage the mating surface.





4. For proper reinstallation, paint matching marks on one side of the bearing cap.

CAUTION:
^ For matching mark, use paint. Do not damage bearing caps and gear carrier.
^ Bearing caps are line-board during manufacture. The matching marks are used to reinstall them in their original positions.





5. Remove bearing caps.





6. Lift differential case assembly out with suitable tool.





^ Keep side bearing outer races together with inner race. Do not mix them up. Also, keep side bearing adjusting washers together with bearings.
7. Remove housing spacer.





8. Remove side bearing inner races, using pullers and the base.
Tool number
A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)

CAUTION:
^ To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
^ It is not necessary to remove side bearing inner race except it is replaced.





9. For proper reinstallation, paint matching mark on one differential case assembly.

CAUTION: For matching mark, use paint. Do not damage differential case and drive gear.

10. Remove drive gear mounting bolts.
11. Tap drive gear off differential case assembly with a soft hammer.

CAUTION: Tap evenly all around to keep drive gear from bending.





12. Remove lock pin of pinion mate shaft with punch from drive gear side.





13. Remove pinion mate shaft.





14. Turn pinion mate gear, then remove pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from differential case.

Drive Pinion Assembly





1. Remove side shaft assembly. Refer to "Side Shaft".
2. Remove differential assembly. Refer to "Differential Assembly".
3. Remove drive pinion lock nut using flange wrench.
Tool number: KV38108300 (J-44195)





4. Put matching mark on the end of drive pinion. The matching mark should be in line with the matching mark A on companion flange.

CAUTION: For matching mark, use paint. Do not damage companion flange and drive pinion.

NOTE: The matching mark A on the final drive companion flange indicates the maximum vertical runout position. When replacing companion flange, matching mark is not necessary.





5. Remove companion flange using the suitable puller.





6. Press drive pinion assembly out of gear carrier. (Together with collapsible spacer.)

CAUTION: Do not drop drive pinion assembly.





7. Remove pinion rear bearing inner race and drive pinion height adjusting washer.
Tool number: ST30031000 (J-22912-01)





8. Remove front oil seal.

CAUTION: Be careful not to damage gear carrier.

9. Remove pinion front bearing inner race.
10. Remove collapsible spacer.





11. Tap pinion front/rear bearing outer races uniformly a brass rod or equivalent to removed.

CAUTION: Be careful not to damage gear carrier.

ASSEMBLY
Drive Pinion Assembly





1. Install front and rear bearing outer races using drifts.
Tool number
A: ST30611000 (J-25742-1)
B: ST30613000 (J-25742-3)
C: KV38100200 (J-26233)

CAUTION:
^ At first, using a hammer, tap bearing outer race until it becomes flat to gear carrier.
^ Do not reuse pinion front and rear bearing outer race.

2. Select drive pinion height adjusting washer. Refer to "Pinion Gear Height".





3. Install selected drive pinion height adjusting washer to drive pinion. Press pinion rear bearing inner race to it, using drift.
Tool number: ST30901000 (J-26010-01)

CAUTION:
^ Pay attention to the direction of pinion height adjusting washer. (Assemble as shown in the figure.)
^ Do not reuse pinion rear bearing inner race.





4. Assemble collapsible spacer to drive pinion.

CAUTION: Do not reuse collapsible spacer.

5. Apply gear oil to pinion rear bearing, and assemble drive pinion into gear carrier.





6. Apply gear oil to pinion front bearing, and assemble pinion front bearing inner race to drive pinion assembly.

CAUTION: Do not reuse pinion front bearing inner race.





7. Using the drift, press the pinion front bearing inner race to drive pinion as far as drive pinion lock nut can be tightened.
Tool number: ST33200000 (J-26082)





8. Using the drift, install front oil seal until it becomes flush with the case end.
Tool number
A: ST30720000 (J-25405)
B: ST27863000 (-)

CAUTION:
^ Do not reuse oil seal.
^ When installing, do not incline oil seal.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.





9. Install companion flange.

NOTE: When reusing drive pinion, align the matching mark of drive pinion with the matching mark A of companion flange, then install companion flange.





10. Apply gear oil to the thread and seat of drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion.

CAUTION: Do not reuse drive pinion lock nut.

11. Adjust the drive pinion lock nut tightening torque and pinion bearing preload torque.
Tool number
A: KV38108300 (J-44195)
B: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 186 - 294 Nm (19 - 29 kg-m, 138 - 216 ft. lbs.)
Drive pinion bearing preload: 1.08 - 1.66 Nm (0.11 - 0.16 kg-m, 10 - 14 inch lbs.)

CAUTION:
^ Adjust the lower limit of the drive pinion lock nut tightening torque first.
^ If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Do not loosen drive pinion lock nut to adjust the preload torque.
^ After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.

12. Install differential case assembly. Refer to "Differential Assembly".

CAUTION: Do not install rear cover yet.

13. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion flange runout. Refer to "Drive Gear Runout", "Tooth Contact", "Backlash", "Companion Flange Runout". Recheck above items. Readjust the above description, if necessary.
14. Check total preload torque. Refer to "Total Preload Torque".
15. Install rear cover. Refer to "Differential Assembly".
16. Install side shaft assembly. Refer to "Side Shaft".

Differential Assembly





1. Install side gear thrust washers with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the side gears.





2. Install side gears and thrust washers into differential case.

CAUTION: Make sure that the circular clip is installed to side gears.

3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and install them into differential case after installing thrust washer to pinion mate gear.





4. Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to "Differential Side Gear Clearance".





6. Drive a lock pin into pinion mate shaft, using punch. Make sure lock pin is flush with differential case.

CAUTION: Do not reuse lock pin.





7. Align the matching mark of differential case with the mark of drive gear, then place drive gear.





8. Apply thread locking sealant into the thread hole of drive gear.
^ Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to "Recommended Chemical Products and Sealants".

CAUTION: Drive gear back and threaded holes shall be cleaned and decreased sufficiently.





9. Install drive gear on the mounting bolts, and then tighten to the specified torque. Refer to "COMPONENTS".

CAUTION:
^ Tighten bolts in a crisscross fashion.
^ After tightening the bolt to the specified torque, tighten the bolts additionally by turning the bolts 31 to 36 degrees.





10. Press side bearing inner races to differential case, using drift and base.
Tool number
A: ST33230000 (J-35867)
B: ST33061000 (J-8107-2)

CAUTION: Do not reuse side bearing inner race.

11. Install housing spacer.





12. Apply gear oil to side bearings, and install differential case assembly with side bearing outer races into gear carrier.





13. Insert left and right original side bearing adjusting washers in place between side bearings and gear carrier, with tool.
Tool number: KV38100600 (J-25267)





14. Align matching mark on bearing cap with that on gear carrier.
15. Install bearing caps and tighten bearing cap mounting bolts to the specified torque. Refer to "COMPONENTS".





16. Using the drift, drive side oil seals until it becomes flush with the case end.
Tool number
A: ST30720000 (J-25405)
B: ST27863000 (-)

CAUTION:
^ Do not reuse oil seal.
^ When installing, do not incline oil seal.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.

17. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque. Refer to "Drive Gear Runout", "Tooth Contact", "Backlash", "Total Preload Torque". Recheck above items. Readjust the above description, if necessary.





18. Apply sealant to mating surface of rear cover.
^ Use Genuine Silicone RTV or equivalent. Refer to "Recommended Chemical Products and Sealants".

CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.

19. Install rear cover on gear carrier and tighten mounting bolts with the specified torque. Refer to "COMPONENTS".
20. Install side shaft assembly. Refer to "Side Shaft".

Side Shaft





1. Press side shaft bearing to side shaft.

CAUTION: Do not reuse bearing.

2. Install snap ring (shaft side).
3. Install side shaft assembly into gear carrier.
4. Install snap ring (hole side).





5. Using the drift, drive side oil seals until it becomes flush with the case end.
Tool number
A: ST30720000 (J-25405)
B: ST27863000 (-)

CAUTION:
^ Do not reuse oil seal.
^ When installing, do not incline oil seal.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.