Assembly

Front Differential Carrier (1 Of 2):

Front Differential Carrier (2 Of 2):

1. If the vehicle came w/ Automatic Differential Disengagement (ADD), using the 09950 60010 (09951 - 00380)Special Service Tool (SST) and a press, install two new bearings. The bearing press in depth is 0.3 +/- 0.3 mm (0.012 +/- 0.012 inch).
2. Assemble the differential case, doing these steps.





a. Install the two proper thrust washers on the two side gears.

NOTE: Using the specifications below, select two thrust washers which will ensure that the backlash is within the specifications. The Washer thickness are as follows:
Thickness: 0.96-1.04 mm (0.0378-0.0409 inch).
Thickness: 1.16-1.24 mm (0.0457-0.0488 inch).
Thickness: 1.06-1.14 mm (0.0417-0.0449 inch).
Thickness: 1.36-1.34 mm (0.0496-0.0528 inch).

b. Install the two side gears, pinion gears, pinion gear thrust washers and pinion shaft in the differential case.

NOTE: 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 differential case. The backlash should be 0 - 0.20 mm (0 - 0.0079 inch). If the backlash is not within the specification, install the two side gear thrust washers with different thicknesses.

3. Install the straight pin and the stake differential case by performing the following.





a. Using a pin punch and hammer, install the straight pin through the differential case and hole of the pinion shaft.
b. Stake the differential case.

4. Install the ring gear on the differential case after doing the following.
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 boiling water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

NOTE: Align the matchmarks on the ring gear and differential case.

e. Temporarily install five new lock plates and ten bolts so that the bolt holes in the ring gear and differential case are not misaligned.
f. After the ring gear has cooled sufficiently, tighten the ring gear set bolts to 97 Nm (71 ft. lbs.).





g. Using a drift punch and hammer, stake the five lock plates.

NOTE: Stake one claw flush with the flat surface of the bolt. For the claw contacting the protruding portion of the bolt, stake only the half on the tightening side.





5. Using the 09226-10010 SST and a press, install the two side bearings into the differential case.
6. Install the side bearing outer races by performing the following procedures.

NOTE: When replacing the two side bearings, fit the two thinnest washers to each bearing and when reusing the bearings; fit the washers with the same thickness as removed.

a. Install a new plate washer to the side bearing retainer.





b. Using the 09950-0020 (09951-00790), 09950-70010 (09951-07150) SST and a press, install the bearing outer race.
c. Install a new plate washer to the differential carrier.





d. Using 09950-0020 (09951 - 00790), 09950-70010 (09951-07150) SST and a press, install the bearing outer race.





7. Using the 09570-22011 SST, install the drive pinion front and rear bearing outer races.
8. Install the drive pinion front bearing by performing these steps.
a. Install the washer on the drive pinion.

NOTE: First fit a washer with the same thickness with the removed washer, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.





b. Using the 09506-30012 SST and a press, install the front bearing onto the drive pinion.

9. Temporarily adjust the drive pinion preload, doing the followinging.
a. Install the drive pinion and oil slinger.

NOTE: Assemble the spacer and oil seal after adjusting the ring gear tooth contact pattern.





b. Using the 09950-30010 (09951 -03010, 09953-03010, 09954-03010, 09955-3030, 0995-03020), install the rear bearing, oil slinger and 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 the 09330-00021 SST to hold the flange, tighten the nut.

NOTE: As there is no spacer, tighten the nut a lime at a time, being careful not to overtighten it.





e. Using a torque wrench, measure the preload. Preload (at starting) should be as follows.
^ New Bearing: 1.2- 1.9 Nm (10.4- 16.5 inch lbs.)
^ Reused Bearing: 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.)

10. Install the differential case in the differential carrier.
11. Adjust the ring gear backlash, doing the following.
a. Install the side bearing retainer with the ten bolts, tightening them to 69 Nm (51 ft. lbs.).





b. Using the 09564-32011 SST and a dial indicator, measure the ring gear backlash. The backlash should be 0.10 - 0.18 mm (0.0039 - 0.0070 inch).
c. If it is not within the specification, adjust it by either in creasing or decreasing the washers on both sides by an equal amount.

NOTE: There should be no clearance between the plate washer and case. Make sure that there is ring gear backlash. The washer thickness are as follows.
(1): 2.00-2.02 mm (0.0787-0.0795 inch).
(2): 2.03-2.05 mm (0.0799-0.0807 inch).
(3): 2.06-2.08 mm (0.0811-0.0819 inch).
(4): 2.09-2.11 mm (0.0823-0.0831 inch).
(5): 2.12-2.14 mm (0.0835-0.0843 inch).
(6): 2.15-2.17 mm (0.0846-0.0854 inch).
(7): 2.18-2.20 mm (0.0858 0.0866 inch).
(8): 2.21-2.23 mm (0.0870 0.0878 inch).
(9): 2.24-2.26 mm (0.0882-0.0890 inch).
(10): 2.27-2.29 mm (0.0894-0.0902 inch).
(11): 2.30-2.32 mm (0.0906-0.0913 inch).
(12): 2.33-2.35 mm (0.0917-0.0925 inch).
(12): 2.36-2.38 mm (0.0929-0.0937 inch).
(13): 2.39-2.41 mm (0.0941-0.0949 inch).
(14): 2.42-2.44 mm (0.0953-0.0961 inch).
(15): 2.45-2.47 mm (0.0965-0.0972 inch).
(16): 2.48-2.50 mm (0.0976-0.0984 inch).
(17): 2.51-2.53 mm (0.0988-0.0996 inch).
(18): 2.54-2.56 mm (0.1000-0.1008 inch).
(19): 2.57-2.59 mm (0.1012-0.1020 inch).
(20): 2.60-2.62 mm (0.1024-0.1031 inch).
(21): 2.63-2.65 mm (0.1035-0.1043 inch).
(22): 2.66-2.68 mm (0.1047-0.1055 inch).
(23): 2.69-2.71 mm (0.1059-0.1067 inch).
(24): 2.72-2.74 mm (0.1071-0.1079 inch).
(25): 2.75-2.77 mm (0.1083-0.1091 inch).
(26): 2.78-2.80 mm (0.1094-0.1102 inch).

12. Using a torque wrench, measure the total preload with the teeth of the drive pinion and ring gear in contact. The total preload (at starting) should be 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.).
13. Inspect the tooth contact between the ring gear and the drive pinion by performing these procedures.
a. Remove the side bearing retainer and differential case.





b. Coat three or four teeth at the three different positions on the ring gear with red lead.
c. Install the differential case and side bearing retainer, tightening it to 69 Nm (51 ft. lbs.).
d. Hold the companion flange firmly and rotate the ring gear in both directions.
e. Remove the side bearing retainer and differential case.





f. Inspect the tooth contact pattern.





NOTE: If the teeth are not contacting properly, use the following chart to select a proper washer for correction.
(1): 1.69-1.71 mm (0.0665-0.0673 inch).
(2): 1.72-1.74 mm (0.0677-0.0685 inch).
(3): 1.75-1.77 mm (0.0689-0.0697 inch).
(4): 1.78-1.80 mm (0.0701-0.0709 inch).
(5): 1.81-1.83 mm (0.0713-0.0720 inch).
(6): 1.84-1.86 mm (0.0724-0.0732 inch).
(7): 1.87-1.89 mm (0.0736-0.0744 inch).
(8): 1.90-1.92 mm (0.0748-0.0756 inch).
(9): 1.93-1.95 mm (0.0760-0.0768 inch).
(10): 1.96-1.98 mm (0.0772-0.0780 inch).
(11): 1.99-2.01 mm (0.0783-0.0791 inch).
(12): 2.02-2.04 mm (0.0795-0.0803 inch).
(13): 2.05-2.07 mm (0.0807-0.0815 inch).
(14): 2.08-2.10 mm (0.0819-0.0827 inch).
(15): 2.11-2.13 mm (0.0831-0.0839 inch).
(16): 2.14-2.16 mm (0.0843-0.0850 inch).
(17): 2.17-2.19 mm (0.0854-0.0862 inch).
(18): 2.20-2.22 mm (0.0866-0.0874 inch).
(19): 2.23-2.25 mm (0.0878-0.0886 inch).
(20): 2.26-2.28 mm (0.0890-0.0898 inch).
(21): 2.29-2.31 mm (0.0902-0.0909 inch).
(22): 2.32-2.34 mm (0.0913-0.0921 inch).

14. Remove the companion flange and the oil slinger.
15. Remove the rear bearing.
16. Install a new bearing spacer, rear bearing and oil slinger by performing the following.
a. Install a new bearing spacer and place the rear bearing and oil slinger.





b. Using the 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 0995-03020) SST and the companion flange, install the rear bearing, then remove the companion flange.

17. Install the oil seal by doing the following.
a. Coat a new oil seal lip with MP grease.





b. Using the 09554-22010 SST and a hammer, install the oil seal. The oil seal drive in depth is 4.5 mm (0.177 inch).

18. Install the companion flange by performing the following.
a. Place the companion flange on the drive pinion.
b. Coat the threads of a new nut with hypoid gear oil.





c. Using 09330-00021 SST to hold the flange, tighten the nut to 108 Nm (80 ft. lbs.).

19. Adjust the drive pinion preload.






NOTE: Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. The preload (at starting) should be as follows.
^ New Bearing: 1.2 - 1.9 Nm (10.4 - 16.5 inch lbs.).

^ Reused Bearing: 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.).

a. If the preload is greater than the specification, replace the bearing spacer.
b. 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. The maximum torque should be 223 Nm (165 ft. lbs.).
c. If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the nut to reduce the preload.

20. Install the differential case.
21. Install the side bearing retainer, performing these functions.
a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and side bearing retainer.
b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.





c. Apply Part No. 0882-00090, THREE BOND 1281 or equivalent FIPG to the side bearing retainer, as shown.

NOTE: Install the side bearing retainer within 10 minutes after applying the FIPG.

d. Install the side bearing retainer with the ten bolts, tightening the bolts to 69 Nm (51 ft. lbs.).

22. Check the total preload.
23. Recheck the ring gear backlash.
24. Recheck the tooth contact between the ring gear and the drive pinion.
25. Check the runout of the companion flange.
26. Stake the drive pinion nut.
27. Install the side oil seal, performing the following.





a. Using the 09608-32010 SST and a plastic hammer, install a new oil seal until its surface is flush with the differential carrier end.
b. Coat the oil seal lip with MP grease.

28. If the vehicle came w/ A.D.D., install the intermediate shaft, by performing the following.
a. Install a new snap ring to the shaft.





b. Using a plastic hammer, install the shaft to the differential case.
c. Check that there is 2 - 3 mm (0.08 - 0.12 inch) of play in axial direction.
d. Check that the intermediate shaft will not come out by trying to pull it completely out by hand.

29. If the vehicle came w/ A.D.D., install the clutch case to the differential tube by doing these steps.





a. Install a new O-ring to the tube.
b. Coat the O-ring with MP grease.
c. Install the clutch case to the tube.
d. Using a (E14) torx socket , tighten the two torx bolts to 78 Nm (58 ft. lbs.).

30. If the vehicle came w/ A.D.D.,install the clutch sleeve
31. Install the differential tube to the differential by performing these steps.
a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential and clutch case.
b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.





c. Apply Part No.0882-00090, THREE BOND 1281 or equivalent FIPG to the differential, as shown.

NOTE: Install the differential tube within ten minutes after applying FIPG.

d. Install the differential tube to the differential.
e) Clean the threads of the 4 bolts (w/o A.D.D.) or two torx bolts (w/ A.D.D.) and retainer bolt holes with toluene or trichloroethylene.
f. Apply Part No. 0883-00070, THREE BOND 1324 or equivalent adhesive to two or three threads of the bolts end.





g. Using a (E14) torx socket , tighten the four bolts (w/o A.D.D.) to 105 Nm (77 ft. lbs.) or the four torx bolts (w/ A.D.D.) to 78 Nm (58 ft. lbs.).

32. If the vehicle came w/ A.D.D.,install the A.D.D. actuator by performing these steps.
a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the actuator and clutch case.
b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.





c. Apply Part No. 0882-00090, THREE BOND 1281 or equivalent FIPG to the clutch case, as shown.

NOTE: Install the actuator within ten minutes after applying the FIPG.

d. Tighten the four bolts to 21 Nm (15 ft. lbs.).