Assembly
Differential Carrier:
ASSEMBLY
1. W/A.D.D.: Install new bearings. Using SST 09950-60010 (09951-00380) and a press, install new bearings.
Bearing press in depth: 0.3 ± 0.3 mm (0.012 ± 0.012 inch)
2. Assemble differential case.
a. Install the proper thrust washers on the side gears.
Washer thickness:
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)
HINT: Select thrust washers which will ensure that the backlash is within the specifications.
b. Install the side gears, pinion gears, pinion gear thrust washers and pinion shaft in the differential case.
HINT: Align the holes of the differential case and pinion shaft.
c. 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 - 0.20 mm (0 - 0.0079 inch)
3. Install straight pin and stake differential case.
a. Using a pin punch and a hammer, install the straight pin through the differential case and hole of the pinion shaft
b. Stake the differential case.
4. 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. Temporarily install 5 new lock plates and 10 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 ring gear set bolts.
Torque to 97 Nm (71 ft. lbs.)
g. Using a hammer and a drift. punch, stake the lock plates.
HINT: 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 portion of the tightening side.
5. Install side bearings. Using SST 09226-10010 and a press, install the bearing into the differential case.
6. Install side bearing outer races.
HINT: When replacing the side bearings, fit the 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 bearing retainer.
b. Using SST 09950-60020 (09951-007903, 09950-70010 (09951-07150) and a press, install the bearing outer race.
c. Install a new plate washer to the differential carrier.
d. Using SST 09950-60020 (09951-00790), 09950-70010 (09951-07150) and a press, install the bearing outer race.
7. Install drive pinion front and rear bearing outer races. Using SST 09570-22011, install the outer races.
8. Install drive pinion front bearing.
a. Install the washer on the drive pinion.
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.
b. Using SST 09506-30012 and a press, install the front bearing onto the drive pinion.
9. Temporarily adjust drive pinion preload.
a. Install the drive pinion and oil slinger.
HINT: Assemble the spacer and oil seal after adjusting the ring gear tooth contact pattern.
b. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020), 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 SST 09330-00021 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.
New bearing preload (at starting): 1.2 - 1.9 Nm (10.4 - 16.5 inch lbs.)
Reused bearing preload (at starting): 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.)
10. Install differential case in differential carrier.
11. Adjust ring gear backlash.
a. Install the side bearing retainer with the 10 bolts.
Torque to 69 Nm (51 ft. lbs.)
b. Using SST 09564-32011 and a dial indicator, measure the ring gear backlash. If it is not within the specification, adjust by either in creasing or decreasing the washers on both sides by an equal amount.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
HINT: There should be no clearance between the plate washer and case. Ensure that there is ring gear backlash.
Washer thickness:
2.00 - 2.02 mm (0.0787 - 0.0795 inch)
2.03 - 2.05 mm (0.0799 - 0.0807 inch)
2.06 - 2.08 mm (0.0811 - 0.0819 inch)
2.09 - 2.11 mm (0.0823 - 0.0831 inch)
2.12 - 2.14 mm (0.0835 - 0.0843 inch)
2.15 - 2.17 mm (0.0846 - 0.0854 inch)
2.18 - 2.20 mm (0.0858 - 0.0866 inch)
2.21 - 2.23 mm (0.0870 - 0.0878 inch)
2.24 - 2.26 mm (0.0882 - 0.0890 inch)
2.27 - 2.29 mm (0.0894 - 0.0902 inch)
2.30 - 2.32 mm (0.0906 - 0.0913 inch)
2.33 - 2.35 mm (0.0917 - 0.0925 inch)
2.36 - 2.38 mm (0.0929 - 0.0937 inch)
2.39 - 2.41 mm (0.0941 - 0.0949 inch)
2.42 - 2.44 mm (0.0953 - 0.0961 inch)
2.45 - 2.47 mm (0.0965 - 0.0972 inch)
2.48 - 2.50 mm (0.0976 - 0.0984 inch)
2.51 - 2.53 mm (0.0988 - 0.0996 inch)
2.54 - 2.56 mm (0.1000 - 0.1008 inch)
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)
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. Remove the side bearing retainer and differential case.
b. Coat 3 or 4 teeth at three different positions on the ring gear with red lead.
c. Install the differential case and side bearing retainer.
Torque 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. If the teeth are not contacting properly, use the following chart to select a proper washer for correction.
Washer thickness
1.69 - 1.71 mm (0.0665 - 0.0673 inch)
1.72 - 1.74 mm (0.0677 - 0.0685 inch)
1.75 - 1.77 mm (0.0689 - 0.0697 inch)
1.78 - 1.80 mm (0.0701 - 0.0709 inch)
1.81 - 1.83 mm (0.0713 - 0.0720 inch)
1.84 - 1.86 mm (0.0724 - 0.0732 inch)
1.87 - 1.89 mm (0.0736 - 0.0744 inch)
1.90 - 1.92 mm (0.0748 - 0.0756 inch)
1.93 - 1.95 mm (0.0760 - 0.0768 inch)
1.96 - 1.98 mm (0.0772 - 0.0780 inch)
1.99 - 2.01 mm (0.0783 - 0.0791 inch)
2.02 - 2.04 mm (0.0795 - 0.0803 inch)
2.05 - 2.07 mm (0.0807 - 0.0815 inch)
2.08 - 2.10 mm (0.0819 - 0.0827 inch)
2.11 - 2.13 mm (0.0831 - 0.0839 inch)
2.14 - 2.16 mm (0.0843 - 0.0850 inch)
2.17 - 2.19 mm (0.0854 - 0.0862 inch)
2.20 - 2.22 mm (0.0866 - 0.0874 inch)
2.23 - 2.25 mm (0.0878 - 0.0886 inch)
2.26 - 2.28 mm (0.0890 - 0.0898 inch)
2.29 - 2.31 mm (0.0902 - 0.0909 inch)
2.32 - 2.34 mm (0.0913 - 0.0921 inch)
14. Remove companion flange and oil slinger.
15. Remove rear bearing.
16. Install new bearing spacer, rear bearing and oil slinger.
a. Install a new bearing spacer and place the rear bearing and oil slinger.
b. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) and the companion flange, install the rear bearing then remove the companion flange.
17. Install oil seal.
a. Coat a new oil seal lip with MP grease.
b. Using SST 09554-22010 and a hammer, install the oil seal.
Oil seal drive in depth: 4.5 mm (0.177 inch)
18. Install companion flange.
a. Place the companion flange on the drive pinion.
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 108 Nm (80 ft. lbs.)
19. Adjust drive pinion preload. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
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: 223 Nm (165 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 nut to reduce the preload.
New bearing preload (at starting): 1.2 - 1.9 Nm (10.4 - 16.5 inch lbs.)
Reused bearing preload (at starting): 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.) If the preload is greater than the specification, replace the bearing spacer.
20. Install differential case.
21. Install side bearing retainer.
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 FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent, to the side bearing retainer, as shown.
HINT: Install the side bearing retainer within 10 minutes after applying FIPG.
d. Install the side bearing retainer with the 10 bolts.
Torque to 69 Nm (51 ft. lbs.)
22. Check total preload.
23. Recheck ring gear backlash.
24. Recheck tooth contact between ring gear and drive pinion.
25. Check runout of companion flange.
26. Stake drive pinion nut.
27. Install side oil seal. Using SST 09608-32010 and a hammer, install a new oil seal until its surface is flush with the differential carrier end.
Side oil seal drive in depth: 0 mm (0 inch)
b. Coat the oil seal lip with MP geese.
28. W/ A.D.D.: Install intermediate shaft.
a. Install a new snap ring to the shaft
b. Using a plastic-faced 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. W/ A.D.D.: Install clutch case to differential tube.
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. Torque the 2 torx bolts using Torx socket E14 (Part No. 09044-00010, or locally manufactured tool).
Torque to 78 Nm (58 ft. lbs.)
30. W/ A.D.D.: Install clutch sleeve.
31. Install differential tube to differential.
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 FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent, to the differential, as shown.
HINT: Install the differential tube within 10 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 2 torx bolts (W/ A.D.D.) and retainer bolt holes with toluene or trichloroethylene.
f. Apply adhesive Part No. 08833-00070, THREE BOND 1324, or equivalent, to 2 or 3 threads of the bolts end.
g. Torque the 4 bolts (W/O A.D.D.) or 4 torx bolts (W/ A. D.D.) using Torx socket E14 (Part No. 09044-00010 or locally manufactured tool).
Torque:
W/O A.D.D.: 105 Nm (77 ft. lbs.)
W/ A.D.D.: 78 Nm (58 ft. lbs.)
32. W/ A.D.D.: Install A.D.D. actuator.
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: Part No. 08826-00090, THREE BOND 1281, or equivalent, to the clutch case, as shown.
HINT: Install the actuator within 10 minutes after applying FIPG.
d. Torque the 4 bolts.
Torque to 21 Nm (15 ft. lbs.)