Assembly

1. Assemble differential case.
a. Install the two proper thrust washers to the side gears.

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





b. Install the two 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 specification, replace the thrust washers.
d. Using a pin punch and hammer, install 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 Special Service Tool (SST) 09506-35010, 09950-60010 (09951-00480), 09950-70010 (09951-07150) or equivalents, and a press, install the two 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 boiling water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.





e. Align the matchmarks on the ring gear and differential case.
f. After the ring gear cools down enough, torque the set bolts to which thread lock has been applied.
Thread Lock: THREE BOND 1360K or equivalent
Torque: 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 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 09950-60010 (09951-00710), 09950-70010 (09951-07150) or equivalents, install a new front bearing outer race to the carrier.
b. Using SST 09950-0010 (09951-0910), 09950-70010 (09951-07150) or equivalents, install a new adjusting washer and install 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 09506-5010 or equivalent, 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 or equivalent, 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 or equivalent, 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 (4.3 - 6.9 inch lbs.).
8. Install differential case in carrier, as follows:
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. 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 (references):
2WD: 0.08 - 0.13 mm (0.0031 - 0.0051 inch)
4WD: 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. 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:
2WD: 0.08 - 0.13 mm (0.0031 - 0.0051 inch)
4WD: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
k. If the backlash not within specification, adjust by either increasing or decreasing the number of washers on both sides by an equal amount.

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

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, tap in the plate washer.





d. Recheck the ring gear backlash.
Backlash:
2WD: 0.08 - 0.13 mm (0.0031 - 0.0051 inch)
4WD: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)





e. If the backlash is not within specification, adjust by either increasing or decreasing the washers on both sides by equal amounts.

HINT: The backlash will change about 0.20 mm (0.0008 inch) with 0.03 mm (0.0012 inch) alteration of the side washer.

11. Install bearing caps.
Align the matchmarks on the two caps and carrier and torque the four bolts.
Torque: 113 Nm (83 ft. lbs.).
12. Measure total preload.
Using a torque wrench, measure the total preload.
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. Turn the companion flange in both directions to inspect the ring gear for proper tooth contact.





If the teeth are not contacting properly, use the chart to select a proper washer for correction.
14. Remove companion flange.
15. Remove front bearing.
16. Install new bearing spacer, washers and front bearing.
a. Install a new bearing spacer and two washers, and place the front bearing.





b. Using SST 09950-30010 or equivalent, 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 Multipurpose (MP) grease.





b. Using SST 09469-17010, 09316-12010 or equivalents, and a press, tap in the oil seal until its surface with the differential carrier end.

NOTE: Connect SST with vinyl tape.

18. Install companion flange.
a. Install the companion flange on the shaft.
b. Coat the threads of a new nut with hypoid gear oil.





c. Using SST 09330-00021 or equivalent to hold the flange, torque the nut.
Torque: 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 preload is greater than the specification, replace the bearing spacer.





- If preload is less than specification, retorque the nut a little at a time with a torque of 13 Nm (9 ft. lbs.) 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. Install differential case in carrier.
21. Recheck total preload.
22. Recheck ring gear backlash.
23. Recheck tooth contact between ring gear and drive pinion.
24. Check runout of companion flange.
25. Stake drive pinion nut.