Part 1
Rear Differential ReassemblyReference: Rear Differential Dismounting and Remounting: Rear
Reference: Rear Differential Disassembly: Rear
Reference: Rear Differential Inspection: Rear
Judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc. after disassembly, prepare replacing parts and proceed to reassembly according to procedures as described.
CAUTION:
^ Drive bevel gear and pinion must be replaced as a set when either replacement becomes necessary.
^ When replacing taper roller bearing, replace as inner race and outer race assembly.
Differential Carrier
For press-fitting drive bevel pinion bearing outer races, use special tools as shown in the figure.
Special Tool
(A): 09924-74510
(B): 09926-68310
(C): 09913-75510
Differential Case
For H25 engine model
1. After applying differential oil to side gear (4), pinions (5), pinion shafts, washer, thrust washer (2) and spring washer (1), install them in differential left case (3).
For correct installing direction of thrust washer (2) and spring washer (1), refer to the figure.
2. When installing pinion shaft No.2 (2) (shorter) into differential case and pinion, insert its "a" side into pinion joint (1).
NOTE: "a" is longer than "b". ("a" > "b")
3. Check pinion gear (1) for smooth rotation.
4. In the same manner as described in Step 1), install thrust washer (2), spring washer (1) and side gear (4).
5. Install differential right case (1) and then tighten bolts to specified torque.
"A": Thread lock cement 99000-32020
Tightening torque
Differential case bolt a: 41 Nm (4.1 kg-m, 30.0 ft. lbs.)
6. Put bevel gear on differential case (1) and fasten them with bolts (2) by tightening them to specified torque. Use thread lock cement for bolts (2).
CAUTION: Use of any other bolts than that specified is prohibited.
"A": Thread lock cement 99000-32020
Tightening torque
Bevel gear bolt a: 85 Nm (8.5 kg-m, 61.5 ft. lbs.) (H25 engine model)
Install special tool (B) to differential case assembly (2) and check that preload is within specification below. If preload exceeds specified value, check if foreign matter is caught or gear is damaged.
Special Tool
(B): 09928-06010-002
Side gear preload
Max. 2.5 Nm (0.25 kg-m, 1.8 ft. lbs.)
For H27 engine model
1. After applying differential oil to differential gear (4), pinions (5), pinion shafts (6), thrust washer (2) and spring washer (1), install them in differential right case (3).
For correct installing direction of thrust washer (2) and spring washer (1), refer to the figure.
2. When installing pinion shaft No.2 (2) (shorter) into differential case and pinion, insert its "a" side into pinion joint (1).
NOTE: "a" is longer than "b". ("a" > "b")
3. Check differential pinion gear (1) for smooth rotation.
4. In the same manner as described in Step 1), install thrust washer (2), spring washer (1) and differential gear (4).
5. Install differential left case (1) and then tighten screws to specified torque.
"A": Thread lock cement 99000-32110
Tightening torque
Differential case screw a: 9 Nm (0.9 kg-m, 6.5 ft. lbs.)
6. Clean and degrease mating surface of drive bevel gear (hypoid gear) (1).
7. Apply thread lock cement to hatched part of drive bevel gear (1) as shown in the figure.
"A": Thread lock cement 99000-32110
8. Put drive bevel gear (3) on differential case (1) and fasten them with bolts (2) by tightening them to specified torque. Use thread lock cement for bolts (2).
CAUTION: Use of any other bolts than that specified is prohibited.
"A": Thread lock cement 99000-32110
Tightening torque
Bevel gear bolt a: Tighten 40 Nm (4.0 kg-m, 29.5 ft. lbs.) + 50° (H27 engine model)
9. Install special tool to differential case assembly (2) and check that preload is within specification. If preload exceeds specified value, check if foreign matter is caught or gear is damaged.
Special Tool
(B): 09928-06510
Side gear preload
Max. 2.5 Nm (0.25 kg-m, 1.8 ft. lbs.)
Differential Side Bearing
1. Press-fit side bearing (1) with special tool and hydraulic press.
Special Tool
(A): 09944-66020
2. Hold bearing press-fitted in Step 1) with holder and press-fit side bearing on the other side.
NOTE: Be sure to use bearing holder for the purpose of protecting lower bearing.
Special Tool
(A): 09944-66020
(B): 09951-16060
Drive Bevel Pinion
To engage drive bevel pinion and gear correctly, it is pre-required to install drive bevel pinion to differential carrier properly by using adjusting shim as described on the followings. Shown below is relative positions of drive bevel pinion, differential carrier and mounting dummy. For H25 engine model
Special Tool
(A): 09900-20607
(B): 09926-78311
(C): 09922-75222
(D): 09951-16070
(E): 09922-77250
(F): 09951-46010
For H27 engine model
Special Tool
(A): 09900-20607
(B): 09926-78320
(C): 09922-75222
(D): 09922-76570
(E): 09951-46010
(F): 09926-78311-002
1. Install special tools with bearings and universal joint flange (2) to differential carrier (1).
NOTE: This installation requires no spacer or oil seal.
For H25 engine model
Special Tool
(B): 09926-78311
(F): 09951-46010 (for M/T model only)
For H27 engine model
Special Tool
(E): 09951-46010
(F): 09926-78311-002
2. Tighten flange nut (1) so that specified bearing preload is obtained.
NOTE:
^ Before taking measurement with spring balance (2) or torque wrench (3), check for rotation by hand and apply small amount of differential oil to bearings.
^ On measuring preload, rotate the drive bevel pinion about 1 rotation per 2 seconds.
For H25 engine model
Special Tool
(B): 09926-78311
(C): 09922-75222
Pinion bearing preload
0.9 - 1.7 Nm (9.0 - 17.0 kg-cm, 7.8 - 14.7 inch lbs.)
Spring measure reading with special tool
1.8 - 3.4 kg (4.0 - 7.5 lb)