Disassembly and Assembly
Rear Differential Disassembly and AssemblyDisassembly
1. Remove differential cover (1).
2. Remove breather plug (2) from differential cover (1).
3. Remove differential side bearing stopper and then remove differential side bearing retainer.
Special Tool (A): 09923-58520
4. Using some appropriate rod (1), drive out differential side bearing outer races (2).
NOTE: When driving out differential side bearing outer races, be very careful not to cause damage to tooth surface of bevel gear.
5. Remove bevel gear assembly (3).
6. Remove bevel gear bolts (1) and then remove drive bevel gear (2).
7. Remove differential side bearings (3).
8. Drive out differential side pinion shaft pin with special tool and hammer.
Special Tool (B): 09922-85811
9. Disassemble differential side gears (2), pinions (3), washers and shaft (4) in differential case (1).
10. Remove caulking of bevel pinion nut with special tool and power wrench (1).
Special Tool (C): 09930-40113
11. Remove companion flange (1) and washer from drive bevel pinion, and then drive out drive bevel pinion.
Special Tool
(D): 09913-85230
(E): 09913-65135
12. Remove rear bearing (2) from drive bevel pinion (1) by using bearing puller (3) and press.
13. Using a hammer and brass bar (1), drive out front bearing outer race (2).
14. Using a hammer and brass bar (1), drive out rear bearing outer race (2).
Rear Differential Reassembly
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 in the following.
CAUTION:
^ Bevel gear and pinion must be replaced as a set when either replacement becomes necessary.
^ When replacing taper roller bearing, replace as inner race & outer race assembly.
Differential carrier
1. Press-fit bevel pinion bearing outer races to differential carrier (1) by using special tools as shown in figure.
Special Tool
(A): 09924-74510
(B): 09951-16090
Differential case
1. After applying differential oil to side gears (4), pinions (5), pinion shaft (3), side washers (1) and pinion washers (2), install them in differential case (6).
NOTE: Used left and right differential side washers are not interchangeable.
2. Check pinion gear (1) for smooth rotation.
3. Align pinion shaft hole position with differential case and drive in differential pinion shaft pin till they are flush with end surface of case.
Special Tool (A): 09922-85811
4. Apply thread lock cement to thread of bevel gear bolts (1).
5. Put bevel gear (2) on differential case (3) and fasten them with 8 bolts (1) by tightening them to specified torque.
CAUTION: Use of any other bolts than that specified is prohibited.
"A": Thread lock cement 99000-32110
Tightening torque
Bevel gear bolts (a): 73 Nm (7.3 kgf-cm, 52.0 ft. lbs.)
Differential side bearing
1. Press-fit differential side bearing (1) with special tool.
Special Tool
(A): 09951-16060
(B): 09924-74510
2. Hold bearing (2) press-fitted in Step 1 with holder and press-fit differential side bearing (1) on the other side.
NOTE: Be sure to use bearing holder for the purpose of protecting lower bearing.
Special Tool
(A): 09951-16060
(B): 09924-74510
(C): 09923-78210
Drive bevel pinion shim adjustment
To mesh bevel pinion and gear correctly, it is prerequired to install bevel pinion to differential carrier properly by using adjusting shim as described on following steps.
Differential unit
1. Install side oil seal to bearing outer race (1). Then apply grease to oil seal lip.
Grease 99000-25010
Special Tool (A): 09913-75520
2. Place bearing outer races (1) on their respective bearings.
NOTE: Used left and right outer races are not interchangeable.
3. After applying differential oil to side bearings, install case assembly (2) in differential carrier (3).
4. Tighten bearing retainer.
Special Tool (B): 09923-58520
5. To measure bevel gear backlash, set dial gauge at right angle to bevel gear tooth, fix drive bevel pinion, tighten both retainers and read dial gauge while moving bevel gear.
NOTE:
^ Be sure to apply measuring tip of dial gauge at right angles to convex side of tooth.
^ As a practical measure following would be recommended to obtain specified backlash and side bearing preload at the same time.
^ Obtain specified backlash by turning both retainers inward lightly.
^ Tighten both retainers further by one notch at a time.
^ Measure at least 4 points on drive bevel gear periphery.
Special Tool
(C): 09900-20606
: 09923-58520
: 09900-20701
Drive bevel gear backlash
Standard: 0.1 - 0.2 mm (0.004 - 0.008 inch)
6. With bevel gear installed, measure rotational torque while turning bevel pinion about 50 rpm by using special tool.
Special Tool (E): 09922-75222
Differential side bearing preload:
(Measured bevel pinion bearing preload) + (3 - 5 kg-cm (2.6 - 4.3 inch lbs.))
Rotational force with special tool:
(Measured bevel pinion rotational force) + (0.6 - 1 kg (1.3 - 2.2 lb))
7. Install retainer stoppers (2).
NOTE: Change shape of retainer stopper depending on position of tooth on retainer (1).
Tightening torque
Retainer stopper bolts (a): 10 Nm (1.0 kgf-cm, 7.5 ft. lbs.)
8. Check gear tooth contact.
Apply red lead paste to tooth of drive bevel gear and turn it by hand to check its contact with drive bevel pinion. Check contact pattern, referring to following chart. If contact pattern is not normal, readjust or replace as necessary according to instruction in chart.
NOTE:
^ Apply red lead paste all around bevel gear but not so much as to become sticky.
^ Be careful not to turn bevel gear more than one full revolution, for it will hinder accurate check.
Gear Tooth Contact
9. Upon completion of gear tooth contact check in Step 8), after applying sealant to breather cover (3), install breather plug (2) to differential cover (4).
10. After applying sealant to differential cover (4), install differential cover (4) to differential carrier (1).
"A": Sealant 99000-31110
Tightening torque
Breather cover bolt (b): 6.0 Nm (0.6 kgf-cm, 4.5 ft. lbs.)
Differential cover bolts 23 Nm (2.3 kgf-cm, 17.0 ft. lbs.)
11. Caulk bevel pinion nut (2) with caulking tool (1) and hammer.