Assembly

Front Differential Carrier - 4 WD:

1. Assemble differential case, as follows:





a. Using Special Service Tool (SST) 09950 - 60010 (09951 - 00370), 09950 - 70010 (09951 - 07150) or equivalents and a press, install two new needle bearings.

Bearing press in depth: 2.0 mm (0.079 inch).





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

NOTE: Using the specifications listed below, select thrust washers which will ensure that the backlash is within specifications. The washer thickness are as follows:

0.96 - 1.04 mm (0.0378-0.0409 inch).
1.06 - 1.14 mm (0.0417-0.0449 inch).
1.16 - 1.24 mm (0.0457-0.0488 inch).
1.26 - 1.34 mm (0.0496-0.0528 inch).

c. 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.





d. Using a dial indicator measure the side gear backlash with holding one pinion gear toward the differential case. If the backlash is not within the specification, install side gear thrust washers with different thicknesses.

Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)

2. Install straight pin and stake differential case, as follows:





a. Using a pin punch and hammer, install the straight pin through the differential case and hole of the pinion shaft.
b. Using a chisel and hammer, stake the out side of the differential case pin hole.

3. Install ring gear on differential case, as follows:
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, torque the ten ring gear set bolts.

Torque: 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 nut. For the claw contacting the protruding portion of the nut, stake only the half portion of the tightening side.





4. Install side bearings. Using SST 09226 - 10010, 09550 - 10012 (09558 - 10010) or equivalents, and a press, install the two side bearings into the differential case.
5. Check ring gear runout, as follows:
a. Install the differential case onto the carrier and install the two plate washers to where there is no play in the bearing.
b. Install two bearing caps.





c. Using a dial indicator, measure the runout of ring gear.

Maximum runout: 0.07 mm (0.0028 inch).





6. Install drive pinion front and rear bearing outer races. Using SST 09950 - 60020 (09951 - 00710), 09950-70010 (09951 -07150) or equivalent for the front and SST 09950 - 60020 (09951 - 00790), 09950-70010 (09951 -07150) or equivalent for the rear and a press, install the drive pinion front and rear bearing outer races.

7. Install drive pinion front bearing, as follows:
a. Install the washer on the drive pinion.

NOTE: 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.





b. Using Special Service Tool (SST) 09506 - 30012 or equivalent, install the front bearing onto the drive pinion.

8. Temporarily adjust drive pinion preload, as follows:
a. Install the drive pinion, rear bearing and oil slinger.

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





b. Using the 09950 - 30010 SST, 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, then using SST 09330 - 00021 or equivalent to hold the flange, tighten 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: 1.2 - 1.9 Nm (10.4 - 16.5 inch lbs.).
- Reused bearing: 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.).





9. Install differential case in differential carrier, as follows:
a. Place the two bearing outer races on their respective bearings. Check that the left and right outer races are not interchanged.
b. Install the differential case in the differential carrier.

10. Adjust ring gear backlash, as follows:
a. Only install the plate washer on the ring gear back side.

NOTE: Insure that the ring gear has backlash.





b. Tap on the ring gear with a plastic hammer so that the washer fit to the bearing.





c. Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the differential case.

Backlash (reference): 0.13 mm (0.0051 inch).





d. Select a ring gear back side plate washer, using the backlash as reference.





e. Select a ring gear teeth side plate washer with a thickness which eliminates any clearance between the outer race and case.
f. Remove the plate washes 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. Tap on the ring gear with a plastic hammer so that the washer fit to the bearing.





j. Using a dial indicator, measure the ring gear backlash.

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0070 inch).





k. If not within specification, adjust by either increasing or decreasing the number of washers on both sides by an equal amount.

NOTE: There should be no clearance between the plate washer and case. Ensure that there is ring gear backlash.





11. Adjust side bearing preload, as follows:
a. Remove the ring gear teeth side plate washer and measure the thickness.
b. Using the backlash as a reference, install a new washer of 0.06-0.09 mm (0.0024 - 0.0035 inch) thicker than the washer removed.

NOTE: Select a washer which can be pressed in 2/3 of the way with your finger.

c. Using a plastic hammer, install the plate washer.
d. Recheck the ring gear backlash.

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0070 inch).





e. If not within specification, adjust by either increasing or decreasing the washers on both sides by an equal amount.

NOTE: The backlash will change about 0.02 mm (0.0008 inch) with 0.03 mm (0.0012 inch) alteration of the plate washer.

f. The washer thickness are:

2.57-2.59 mm (0.1012-0.1020 inch).
2.60-2.62 mm (0.1024-0.1031 inch).
2.63-2.65 mm (0.1035-0.1043 inch).
2.66-2.68 mm (0.1047-0.1055 inch).
2.69-2.71 mm (0.1059-0.1067 inch).
2.72-2.74 mm (0.1071-0.1079 inch).
2.75-2.77 mm (0.1083-0.1091 inch).
2.78-2.80 mm (0.1094-0.1102 inch).
2.81-2.83 mm (0.1106-0.1114 inch).
2.84-2.86 mm (0.1118-0.1126 inch).
2.87-2.89 mm (0.1130-0.1138 inch).
2.90-2.92 mm (0.1142-0.1150 inch).
2.93-2.95 mm (0.1154-0.1161 inch).
2.96-2.98 mm (0.1165-0.1173 inch).
2.99-3.01 mm (0.1177-0.1185 inch).
3.02-3.04 mm (0.1189-0.1197 inch).
3.05-3.07 mm (0.1201-0.1209 inch).
3.08-3.10 mm (0.1213-0.1220 inch).
3.11-3.13 mm (0.1224-0.1232 inch).
3.14-3.16 mm (0.1236-0.1244 inch).
3.17-3.19 mm (0.1248-0.1256 inch).
3.20-3.22 mm (0.1260-0.1268 inch).
3.23-3.25 mm (0.1272-0.1280 inch).

12. Install bearing caps. Align the matchmarks on the two caps and carrier.

Torque: 78 Nm (58 ft. lbs.).

13. Measure total preload. Using a torque wrench, measure the total preload.

Total preload (at starting): 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.).

14. Inspect the tooth contact between the ring gear and the drive pinion, as follows:





a. Coat three or four teeth at three different positions on the ring gear with red lead.
b. Hold the companion flange firmly and rotate the ring gear in both directions.








c. Inspect the tooth contact pattern. If the teeth are not contacting properly, use the following specifications to select a proper washer for correction.

2.27 mm (0.0894 inch).
2.30 mm (0.0906 inch).
2.33 mm (0.0917 inch).
2.36 mm (0.0929 inch).
2.39 mm (0.0941 inch)
2.42 mm (0.0953 inch).
2.45 mm (0.0965 inch).
2.48 mm (0.0976 inch).
2.51 mm (0.0988 inch).
2.54 mm (0.1000 inch).
2.57 mm (0.1012 inch).
2.60 mm (0.1024 inch).
2.63 mm (0.1035 inch).
2.66 mm (0.1047 inch).
2.69 mm (0.1059 inch).

15. Install bearing spacer, as follows:
a. Remove the companion flange, oil slinger and rear bearing.





b. Install a new bearing spacer.
c. Install the rear bearing and oil slinger.

16. Install oil seal, as follows:





a. Using SST 09554 - 30011 or equivalent and a hammer, install a new oil seal.

Oil seal drive in depth: 1.5 mm (0.059 inch).

b. Apply MP grease to the oil seal lip.

17. Install companion flange, as follows:





a. Using SST 09950 - 30010 or equivalent, install the companion flange.
b. Coat the threads of a new nut with hypoid gear oil install it.





c. Using SST 09330 - 00021 or equivalent to hold the flange, tighten the nut.

Torque: 108 Nm (80 ft. lbs.).





18. Adjust drive pinion preload. Using a torque wrench, measure the drive pinion preload using the backlash of the drive pinion and ring gear.

Preload (at starting):
- 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.).

- If the preload is greater than the specification, replace the spacer.





- If the preload is less than the specification, retighten the nut a little at a time with a torque of 13 Nm (9 ft. lbs.) until the specified preload is reached.

Maximum torque: 235 Nm (173 ft. lbs.).

- If the maximum torque is exceeded while retightening the nut, replace the spacer and repeat the preload procedure. Do not back off the nut to reduce the preload.

19. Recheck ring gear backlash.
20. Recheck tooth contact between ring gear and drive pinion.
21. Check runout of companion flange.
22. Stake drive pinion nut.
23. Install right hand side gear shaft oil seal, as follows:





a. Using SST 09550 - 22011 (09550 - 00020, 09550 - 00031) or equivalents, and a hammer, install a new oil seal until its surface is flush with the differential carrier end.
b. Apply MP grease to the oil seal lip.

24. Install right hand side gear shaft, as follows:
a. Install a new snap ring to the side gear shaft.





b. Using a plastic hammer, install the side gear shaft to the differential case.

25. Check installation of side gear shaft as follows:
a. Check that there is 2 - 3 mm (0.08 - 0.12 inch) of play in axial direction.
b. Check that the side gear shaft will not come out by trying to pull it completely out by hand.

26. Install intermediate shaft by as follows:
a. Install a new snap ring to the shaft.





b. Using a plastic hammer, install the shaft to the differential case.

27. Check installation of intermediate shaft by doing these steps.
a. Check that there is 2 - 3 mm (0.08 - 0.12 inch) of play in axial direction.
b. Check that the intermediate shaft will not come out by trying to pull it completely out by hand.

28. Install clutch case to side gear shaft tube, as follows:





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, torque the two torx bolts.

Torque: 78 Nm (58 ft. lbs.).

29. Install clutch sleeve.
30. Install left hand side gear shaft to differential carrier by as follows:
a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential -carrier and clutch case.
b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.





c. Apply FIPG to the carrier, as shown.

FIPG: Part No. 08826 - 00090, THREE BOND 1281 or equivalent

NOTE: Install the side gear shaft within ten minutes after applying FIPG.

d. Install the left hand side gear shaft to the differential carrier.





e. Using a (E14) torx socket, tighten the four torx bolts.

Torque: 78 Nm (58 ft. lbs.).

31. Install differential carrier cover, doing these steps.
a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier aria carrier cover.
b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.





c. Apply FIPG to the carrier cover, as shown.

FIPG: Part No. 08826 - 00090, THREE BOND 1281 or equivalent.

NOTE: Install the carrier cover within 10 minutes after applying FIPG.

d. Install the differential carrier cover with the eight bolts.

Torque: 47 Nm (34 ft. lbs.).

32. Install the Automatic Disconnecting Differential (A.D.D.) Actuator as follows:
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 FIPG to the clutch case, as shown.

FIPG: Part No. 08826 - 00090, THREE BOND 1281 or equivalent

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

d. Torque the four bolts.

Torque: 21 Nm (15 ft. lbs.).