Part 1
Assembly1. Installation of differential ring gear
(1) Clean the screw hole of the differential case.
(2) Heat the ring gear up to 100°C {212°F} with hot water.
WARNING:
The ring gear becomes hot. Perform the operation after protecting hands with thick gloves.
(3) Completely wipe off grease and water from the mating surface of the differential case and the ring gear.
(4) Using aluminum plates in between, secure the differential case in a vise.
CAUTION:
Do not overtighten the vise.
(5) Completely wipe off grease and water from the ring gear (mating surface of the differential case).
(6) Align the alignment marks on the differential case and the ring gear, and then quickly install the ring gear to the differential case.
Captions in illustration
CAUTION:
Align the bolt hole of the differential case and the screw hole of the ring gear.
(7) Temporarily tighten 10 differential case bolts several times through 5 new lock plates, and then tighten them to the specified torque.
Standard value:T=97Nm {989kgf-cm} {2,179.32cm-lbf}
CAUTION:
Tighten the bolts after the ring gear cools down sufficiently.
NOTE:
Tighten the bolts diagonally in several stages.
(8) Release the crimps of the lock plate using a chisel and a hammer to counter the rotation.
Captions in illustration
NOTE:
If the crimp contacts the angled portion of the bolt head and should be divided into 2 sections, the section facing the tightening side of the bolt head must be in close contact as shown in the figure.
2. Installation of rear differential case bearing
(1) Using the SST and a press, press-fit the case bearings (inner race LH and RH) into the differential case.
SST 09710-30012 (09710-04081), 398477702
NOTE:
^ Press until the case bearing is in close contact with the differential case.
^ Align the SST in the center of the differential case.
CAUTION:
^ When using new bearings, do not apply differential gear oil.
^ Be careful not to deform the cage of the bearing.
^ When replacing the bearing, replace the outer race and the inner race as a set.
3. Inspection of differential ring gear runout
(1) Install the case bearing (outer race LH and RH) to the case bearing (inner race LH and RH), and install the differential case to the carrier.
CAUTION:
^ When installing the bearing outer races, do not confuse the left and right.
^ When using new bearings, do not apply differential gear oil.
(2) Install the right and left (back face side and tooth face side) side gear shaft washer to the differential carrier while avoiding play of the case bearing.
Captions in illustration
NOTE:
^ When the final gear set (drive pinion & ring gear) and the case bearings are replaced, select a side gear shaft washer with thin thickness and install it.
^ When the drive pinion, ring gear and case bearings are reused, select a side gear shaft washer with the same thickness as that of the one before disassembly and install it.
(3) Install the right and left bearing caps to the differential carrier with 4 bolts.
Captions in illustration
Standard value:T=85Nm {867kgf-cm} {1,911.10cm-lbf}
CAUTION:
The bearing cap and the carrier are manufactured as a unit; do not change the combination.
(4) Contact a dial gauge at a right angle to the back surface of the ring gear.
(5) Check for runout of the ring gear.
Limit: 0.07mm {0.076mm}
(6) Remove 4 bolts, and remove 2 bearing caps from the differential carrier.
Captions in illustration
(7) Remove the right and left side gear shaft washers from the differential carrier.
Captions in illustration
(8) Remove the differential case and right and left case bearings from the differential carrier.
CAUTION:
Be careful not to damage the differential case bearing and the ring gear.
4. Installation of rear drive pinion tapered roller bearing RR
(1) Install the drive pinion washer to the drive pinion.
Captions in illustration
NOTE:
^ In order to prevent the drive pinion washer from dropping, temporarily install the tapered roller bearing RR (inner race).
^ Install the drive pinion washer with the same thickness as that of the removed one.
^ The drive pinion washer has no installation direction.
(2) Using the SST and a press, press-fit the tapered roller bearing RR (inner race) into the drive pinion.
SST 09506-30012
CAUTION:
When using new bearings, do not apply differential gear oil.
(3) Using the SST and a press, press-fit the tapered roller bearing RR (outer race) into the differential carrier.
SST 09950-60020 (09951-00890), 09950-70010 (09951-07200)
Captions in illustration
CAUTION:
When using new bearings, do not apply differential gear oil.
5. Installation of rear drive pinion tapered roller bearing FR
(1) Using the SST and a press, press-fit the tapered roller bearing FR (outer race) into the differential carrier.
SST 09950-60020 (00951-00720), 09950-70010 (09951-07100)
Captions in illustration
CAUTION:
When using new bearings, do not apply differential gear oil.
6. Installation of rear differential dust deflector
(1) Using the SST and a press, press-fit a new dust deflector into the companion flange RR.
SST 499277200, 499225500
CAUTION:
^ When press-fitting, gradually insert the dust deflector while checking the condition.
^ Do not press-fit excessively.
^ Remove a burr if it occurs when press-fitting.
7. Adjustment of differential drive pinion preload
(1) While supporting the drive pinion by hand, install the drive pinion tapered roller bearing FR (inner race) to the differential carrier.
CAUTION:
^ Be careful not to drop the drive pinion.
^ In order to check the tooth contact of the ring gear, install the spacer and oil seal after checking and adjusting the tooth contact.
^ When using new bearings, do not apply differential gear oil.
(2) Install the oil slinger to the differential carrier.
(3) Using the SST, install the companion flange RR to the differential carrier.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)
Captions in illustration
CAUTION:
^ Be careful not to drop the drive pinion. Support it by hands until the SST is installed.
^ The bearing spacer is not installed, therefore, install the companion flange RR until there is a small play in the drive pinion.
NOTE:
^ Apply grease to the thread and end portions of the SST center bolt (09953-03010) before using it.
^ The bolts and nuts used for securing the SST and the companion flange RR are recommended to be M8 �P1.25 with a bolt length of approx. 40 mm {1.6 in}.
(4) Using the SST, secure the companion flange RR.
SST 18355AA000, 18334AA000
Captions in illustration
(5) Using a socket wrench (30 mm) and a torque wrench, gradually tighten a new drive pinion nut to the specified preload.
Limit: T = 338 Nm {3447 kgf-cm} {249.3 ft-lbf}
WARNING:
During operation, support the overhaul stand.
CAUTION:
Note that no bearing spacer is inserted. Therefore, tighten the nut gradually. Never overtighten it.
NOTE:
^ Tighten to approx. 100 Nm {1020 kgf-cm} {73.8 ft-lbf} while checking the preload.
^ Apply differential gear oil to the thread portions of the nut and the drive pinion.
(6) Turn it forward and backward several times to seat the bearing properly.
(7) Using a socket wrench (30 mm) and a torque wrench, check preload of the drive pinion.
Standard value
CAUTION:
For inspection of overall preload, record the preload.
8. Installation of rear differential case SUB-ASSY
(1) Install the case bearing (outer race LH and RH) to the case bearing (inner race LH and RH), and install the differential case to the differential carrier.
CAUTION:
When installing the bearing outer races, do not confuse the left and right.
(2) Install the right and left (back face side and tooth face side) side gear shaft washer to the differential carrier while avoiding play of the case bearing.
Captions in illustration
NOTE:
^ When the final gear set (drive pinion & ring gear) and the differential case bearings are replaced, select a differential side gear shaft washer with thin thickness and install it.
^ When the drive pinion, ring gear and differential case bearings are reused, select a differential side gear shaft washer with the same thickness as that of the disassembled one and install it.
9. Inspection and adjustment of backlash between differential ring gear and differential drive pinion
(1) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(2) Secure the companion flange RR by hand, and inspect the ring gear by moving it.
Standard value: 0.13 to 0.18 mm {0.005 to 0.007 in}
NOTE:
^ Inspect at 3 points or more on the ring gear circumference.
^ Record the measured value for reference when selecting the side gear shaft washer.
^ For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
(3) Select the side gear shaft washer which allows the ring gear's backlash to be within the standard value, and install it to the back face side of the ring gear.
Type of rear differential side gear shaft washer
(4) Using a plastic hammer, lightly tap the differential carrier for better fitting of the case bearing and the side gear shaft washer.
(5) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(6) Secure the companion flange RR by hand, and inspect the backlash by moving the ring gear.
Standard value: 0.13 to 0.18 mm {0.005 to 0.007 in}
(7) If out of the standard, select the side gear shaft washer which allows the ring gear's backlash to be around the standard value, and install it to the back face side of the ring gear.
(8) Select the thickest side gear shaft washer that provides no gap or almost no gap between the end face of the case bearing outer race on the tooth face side of the ring gear and the carrier.
Captions in illustration
(9) Using a plastic hammer, lightly tap the differential carrier for better fitting of the case bearing.
(10) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(11) Secure the companion flange RR by hand, and inspect the backlash by moving the ring gear.
Standard value: 0.13 to 0.18 mm {0.005 to 0.007 in}
(12) If out of the standard, adjust the thickness of the right and left side gear shaft washers, increasing or decreasing by the same amount.
NOTE:
^ Record the measured value for reference when selecting the side gear shaft washer.
^ For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
10. Inspection and adjustment of differential case bearing preload
(1) After adjusting the backlash of the ring gear, remove the side gear shaft washer on the tooth face side of the ring gear.
(2) Using a micrometer, inspect the thickness of the side gear shaft washer.
(3) Select the side gear shaft washer that is 0.06 to 0.09 mm {0.002 to 0.004 in} thicker than the removed side gear shaft washer.
CAUTION:
Install the side gear shaft washer that can be inserted into about two thirds of the way using a finger.
(4) Using the SST and a hammer, press-fit the side gear shaft washers into the differential carrier.
SST 09504-22012
(5) Align the alignment marks on the bearing cap and the differential carrier, and install the bearing cap.
Captions in illustration
(6) Using 4 bolts, tighten the right and left bearing caps.
Standard value:T=85Nm {867kgf-cm} {1,911.10cm-lbf}
CAUTION:
The bearing cap and the carrier are manufactured as a unit; do not change the combination.
(7) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(8) Secure the companion flange RR by hand, and inspect the backlash by moving the ring gear.
Standard value: 0.13 to 0.18 mm {0.005 to 0.007 in}
NOTE:
^ Measure at 3 points or more on the ring gear circumference.
^ If any small backlash is found, replace the side gear shaft washer on the tooth face side of the ring gear with a thicker one.
^ Record the measured value for reference when selecting the side gear shaft washer.
^ For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
^ When adjusting the backlash, bring the average value close to 0.1 mm {0.004 in}.