Assembly
Differential Carrier (3RZ-FE, 5VZ-FE w/o Differential Lock):
1. Assemble differential case.
a. Install the proper thrust washer to the side gears.
Washer thickness:
1.50 mm (0.0590 inch)
1.55 mm (0.0610 inch)
1.60 mm (0.0630 inch)
1.65 mm (0.0650 inch)
1.70 mm (0.0669 inch)
1.75 mm (0.0689 inch)
1.80 mm (0.0709 inch)
1.85 mm (0.0728 inch)
1.90 mm (0.0748 inch)
HINT: Select thrust washers which will ensure that the backlash is within the specifications.
b. Install the side gears with the thrust washers, pinion gears, pinion gear thrust washers and pinion shaft.
HINT: Align the holes of the differential case and pinion shaft.
c. Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specification, replace the thrust washers.
d. Using a pin punch and hammer, drive in the straight pin through the holes in the differential case and pinion shaft
e. Using a chisel and hammer, stake the out side of the differential case pin hole.
2. Install side bearings. Using SST 09950-60010 (09951-00480, 09951-00640) 09950-70010 (09951-07150) and a press, install the side bearings into the differential case.
3. Install ring gear on differential case.
a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear to about 100 C (212° F) in boiling water.
c. Carefully remove the ring gear from the water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
HINT: Align the matchmarks on the ring gear and differential case.
e. After the ring gear cools down enough, torque the set bolts to which thread lock has been applied.
Thread lock: Part No. 08833 - 00100, THREE BOND 1360K, or equivalent.
Torque to 125 Nm (92 ft. lbs.)
4. Inspect ring gear runout.
a. Install the differential case into the carrier and install the plate washers to where there is no play in the bearing.
b. Install the bearing cap.
c. Using a dial indicator, measure the runout of ring gear.
Maximum runout: 0.05 mm (0.0020 inch)
5. Install drive pinion bearing outer races and adjusting washer.
a. Using SST 09950-60020 (09951-00710), 09950-70010 (09951-07150) and a press, install a new front bearing outer race to the carrier.
b. Using SST 09950-60020 (09951-00910), 09950-70010 (09951-07150) and a press, install a new adjusting washer and a new rear bearing outer race to the carrier.
HINT: First fit a washer with the same thickness as the washer which was removed, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.
6. Install drive pinion rear bearing. Using SST 09506-35010 and a press, install the rear bearing onto the drive pinion.
7. Temporarily adjust drive pinion preload.
a. Install the drive pinion and front bearing.
HINT: Assemble the spacer, washers and oil seal after adjusting the gear contact pattern.
b. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03050), install the companion flange.
c. Coat the threads of the nut with hypoid gear oil.
d. Adjust the drive pinion preload by tightening the companion flange nut. Using SST 09330-00021 to hold the flange, torque the nut.
NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.
e. Using a torque wrench, measure the preload.
Preload (at starting):
New bearing: 1.0 - 1.6 Nm (8.7 - 13.9 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (4.4 - 6.9 inch lbs.)
8. Install differential case in carrier.
a. Place the bearing outer races on their respective bearings. Make sure the left and right races are not interchanged.
b. Install the differential case in the carrier.
9. Adjust ring gear backlash.
a. Only install the plate washer on the ring gear backside.
HINT: Ensure that the ring gear has a backlash.
b. Using a plastic hammer, snug down the washer and bearing by tapping the ring gear.
c. Hold the side bearing boss on the teeth surface of the ring gear and measure the backlash.
Backlash (reference): 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
d. Select a ring gear back side plate washer, using the backlash as reference.
e. Select a ring gear teeth side plate washer of a thickness which eliminates any clearance between the outer race and case.
f. Remove the plate washers and differential case.
g. Install the plate washer into the ring gear back side of the carrier.
h. Place the other plate washer onto the differential case together with the outer race, and install the differential case with the outer race into the carrier.
i. Using a plastic hammer, snug down the washer and bearing by tapping the ring gear.
j. Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
k. If the backlash is not within the specification, adjust by either increasing or decreasing the number of washers on both sides by an equal amount. Ensure that there is ring gear backlash.
HINT: There should be no clearance between the plate washer and case.
10. Adjust side bearing preload.
a. after adjustment with the backlash as reference, remove the ring gear teeth side plate washer and measure the thickness.
b. Install a new washer of 0.06 - 0.09 mm (0.0024 - 0.0035 inch) thicker than the washer removed.
HINT: Select a washer which can be pressed in 2/3 of the way by finger.
c. Using a plastic hammer, install the plate washer.
d. Recheck the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
If the backlash is not within the specification, adjust by either increasing or decreasing the washers on both sides by equal amounts.
HINT: The backlash will change about 0.20 mm (0.0079 inch) with 0.03 mm (0.0012 inch) alteration of the side washer.
Mark and Washer thickness:
58 2.58 (0.1015)
60 2.60 (0.1024)
62 2.62 (0.1031)
64 2.64 (0.1039)
66 2.66 (0.1047)
68 2.68 (0.1055)
70 2.70 (0.1063)
72 2.72 (0.1071)
74 2.74 (0.1079)
76 2.76 (0.1087)
78 2.78 (0.1094)
80 2.80 (0.1102)
82 2.82 (0.1110)
84 2.84 (0.1118)
86 2.86 (0.1126)
88 2.88 (0.1134)
90 2.90 (0.1142)
92 2.92 (0.1150)
94 2.94 (0.1157)
96 2.96 (0.1165)
98 2.98 (0.1173)
00 3.00 (0.1181)
02 3.02 (0.1189)
04 3.04 (0.1197)
06 3.06 (0.1205)
08 3.08 (0.1213)
10 3.10 (0.1220)
12 3.12 (0.1228)
14 3.14 (0.1236)
16 3.16 (0.1244)
18 3.18 (0.1252)
20 3.20 (0.1260)
24 3.24 (0.1276)
26 3.26 (0.1283)
28 3.28 (0.1291)
30 3.30 (0.1299)
32 3.32 (0.1307)
34 3.34 (0.1315)
36 3.36 (0.1323)
38 3.38 (0.1331)
40 3.40 (0.1339)
42 3.42 (0.1346)
44 3.44 (0.1354)
46 3.46 (0.1362)
48 3.48 (0.1370)
11. Install side bearing cap.
a. Align the matchmarks on the cap and carrier.
b. Torque the 4 bolts.
Torque to 113 Nm (83 ft. lbs.)
12. Measure total preload. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus: 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.)
13. Inspect tooth contact between ring gear and drive pinion.
a. Coat 3 or 4 teeth at three different position on the ring gear with red lead.
b. Hold the companion flange firmly and rotate the ring gear in both directions.
c. Inspect the teeth pattern. If the teeth are not contacting properly, use the following chart to select a proper washer for correction.
Washer thickness (Mark and Thickness):
87 1.87 mm (0.0736 inch)
88 1.88 mm (0.0740 inch)
89 1.89 mm (0.0744 inch)
90 1.90 mm (0.0748 inch)
91 1.91 mm (0.0752 inch)
92 1.92 mm (0.0756 inch)
93 1.93 mm (0.0760 inch)
94 1.94 mm (0.0764 inch)
95 1.95 mm (0.0768 inch)
96 1.96 mm (0.0772 inch)
97 1.97 mm (0.0776 inch)
98 1.98 mm (0.0780 inch)
99 1.99 mm (0.0783 inch)
00 2.00 mm (0.0787 inch)
01 2.01 mm (0.0791 inch)
02 2.02 mm (0.0795 inch)
03 2.03 mm (0.0799 inch)
04 2.04 mm (0.0803 inch)
05 2.05 mm (0.0807 inch)
06 2.06 mm (0.0811 inch)
07 2.07 mm (0.0815 inch)
08 2.08 mm (0.0819 inch)
09 2.09 mm (0.0823 inch)
10 2.10 mm (0.0827 inch)
11 2.11 mm (0.0831 inch)
12 2.12 mm (0.0835 inch)
13 2.13 mm (0.0839 inch)
14 2.14 mm (0.0843 inch)
15 2.15 mm (0.0846 inch)
16 2.16 mm (0.0850 inch)
17 2.17 mm (0.0854 inch)
18 2.18 mm (0.0858 inch)
19 2.19 mm (0.0862 inch)
20 2.20 mm (0.0866 inch)
21 2.21 mm (0.0870 inch)
22 2.22 mm (0.0874 inch)
23 2.23 mm (0.0878 inch)
24 2.24 mm (0.0882 inch)
25 2.25 mm (0.0886 inch)
26 2.26 mm (0.0890 inch)
27 2.27 mm (0.0894 inch)
28 2.28 mm (0.0898 inch)
14. Remove companion flange.
15. Remove front bearing.
16. Install new bearing spacer, 2 washers and front bearing.
a. install a new bearing spacer and 2 washers, and place the front bearing.
b. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03050) and the companion flange, install the front bearing then remove the companion flange.
17. Install new oil seal.
a. Coat a new oil seal lip with MP grease.
b. Using SST 09649-17010, 09316-12010, install the oil seal until its surface is flush with the differential carrier end.
HINT: Connect SST with vinyl tape.
18. Install companion flange.
a. Place the companion flange.
b. Coat the threads of a new nut with hypoid gear oil.
c. Using SST 09330-00021 to hold the flange, torque the nut.
Torque to 147 Nm (109 ft lbs.)
19. Adjust drive pinion preload. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting):
New bearing: 1.0 - 1.6 Nm (8.7 - 13.9 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.)
If the preload is greater than the specification, replace the bearing spacer.
If the preload is less than the specification, retighten the nut 13 Nm (9 ft. lbs.) a little at a time until the specified preload is reached.
Maximum torque: 451 Nm (333 ft. lbs.)
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the pinion nut to reduce the preload.
20. Check total preload. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus: 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.)
21. Check ring gear backlash. Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
22. Recheck tooth contact between ring gear and drive pinion.
23. Check runout of companion flange.
24. Stake drive pinion nut.