Part 2
OVERHAUL
55. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
a. Install the differential case on the carrier, and install the 2 plate washers so that there is no play in the bearing.
b. Install the 2 bearing caps with the 4 bolts.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.)
c. Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
d. Remove the 2 bearing caps, 2 plate washers and differential carrier.
56. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST and a press, install the front bearing (outer race) to the carrier.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
57. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, install the rear bearing (outer race) to the carrier.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
58. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Install the removed plate washer on the drive pinion.
b. Using SST and a press, install the rear bearing onto the drive pinion.
SST 09506-30012
59. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Install the drive pinion and front bearing.
HINT: Assemble the spacer and oil seal after adjusting the gear contact pattern.
b. Install the oil slinger, as shown in the illustration.
c. Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09950-03010, 09955-03030, 09950-03020)
d. Coat the threads of the nut with hypoid gear oil LSD.
e. Using SST to hold the flange, torque the nut.
SST 09330-00021
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
NOTICE:
^ As there is no spacer, torque a little at a time, being careful not to overtighten it.
^ Apply hypoid gear oil LSD of the nut.
f. Using a torque wrench, measure the preload.
Preload (at starting):
New bearing: 1.1 - 1.7 Nm (11 - 17 kgf-cm, 9.6 - 14.8 inch lbs.)
Reused bearing: 0.6 - 0.9 Nm (6 - 9 kgf-cm, 5.2 - 7.8 inch lbs.)
60. INSTALL DIFFERENTIAL CASE ASSY
a. Place the 2 bearing outer races on their respective bearings. Make sure the right and left races are not interchanged.
61. ADJUST DIFFERENTIAL RING GEAR BACKLASH
a. Install the right and left bearing caps with the 4 bolts.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.
HINT:
^ If the side bearing is new, select a thrust shim of proper thickness from the thinner ones.
^ If the side bearing is reused, select a thrust shim of the same thickness as one installed before disassembly.
b. Snug down the differential case bearing and thrust shim by tapping on the ring gear with a plastic hammer.
c. Set the dial indicator perpendicular to the end of the ring gear face.
d. While holding the rear drive pinion companion flange rear rotate the ring gear and measure the backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
NOTICE: Measure it at 3 points or more on the ring gear periphery. If the measured value is out of the specified value, select a proper thrust shim so that the backlash of the differential ring gear is within the value, and install it to the ring gear back side.
Washer thickness
62. ADJUST TOTAL PRELOAD
a. After adjusting the backlash of the differential ring gear, remove the teeth side thrust shim.
b. Using a micrometer, measure the thickness of the removed thrust shim.
c. Select a new thrust shim 0.06 - 0.09 mm (0.0024 - 0.0035 inch) thicker than the removed one.
HINT: Select a thrust shim, which can be pressed in 2/3 of the way by finger.
d. Using SST and a plastic hammer, drive in the thrust shim.
SST 09504-22011
e. Align the matchmarks on the bearing cap and differential carrier, install the 2 bearing caps.
NOTICE: Make sure the right and left bearing caps are not interchanged.
f. Tighten both bearing caps with the 4 bolts.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.)
g. Set the dial indicator on to the end of the differential ring gear face.
h. While holding the rear drive pinion companion flange rear, rotate the differential ring gear and measure the back lash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
i. If the measured value is out of the specified value, adjust it by increasing or decreasing the thickness of both right and left thrust shims equally.
SST 09504-22011
j. Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus 0.3 - 0.5 Nm (3 - 5 kgf-cm, 2.6 - 4.3 inch lbs.)
63. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.
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 table to select a proper washer for correction.
Washer thickness
64. REMOVE REAR DRIVE PINION NUT (See step 31)
SST 09330-00021
65. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR (See step 32)
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09950-03020)
66. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
67. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (See step 36)
SST 09556-22010
68. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
69. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
70. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Install the oil slinger, as shown in the illustration.
71. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST and a hammer, install a new oil seal.
SST 09550-22010
Oil seal drive in depth: 2.0 - 0.3 mm (0.079 - 0.012 inch)
b. Coat MP grease to the oil seal lip.
72. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, install a new dust deflector.
SST 09223-00010
NOTICE: Be careful not to damage the dust deflector.
73. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using SST, install the companion flange on the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09950-03010, 09955-03030, 09956-03020)
b. Coat the threads of a new nut with hypoid gear oil LSD.
c. Using SST to hold the flange, torque the nut.
SST 09330-00021
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
74. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting):
New bearing: 1.1 - 1.7 Nm (11 - 17 kgf-cm, 9.6 - 14.8 inch lbs.)
Reused bearing: 0.6 - 0.9 Nm (6 - 9 kgf-cm, 5.2 - 7.8 inch lbs.)
^ If the preload is greater than the specification, replace the bearing spacer.
^ If the preload is less than the specification, retorque the nut with 13 Nm (130 kgf-cm, 9 ft. lbs.) of torque at a time until the specified preload is reached.
Torque: 235 Nm (2,400 kgf-cm, 174 ft. lbs.) or less
^ If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure. Do not loosen the pinion nut to reduce the preload.
75. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus 0.3 - 0.5 Nm (3 - 5 kgf-cm, 2.6 - 4-3 inch lbs.)
76. INSPECT DIFFERENTIAL RING GEAR BACKLASH (See step 21)
77. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR (See step 24)
78. INSTALL REAR DRIVE PINION NUT
a. Using a chisel and hammer. stake the drive pinion nut.
79. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL
a. Using SST and a hammer, install 2 new oil seals until they are flush with the carrier end surface.
SST 09550-00032, 09950-70010 (09951-07200)
b. Coat MP grease to the oil seal lip.
80. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT DUST COVER
a. Using a steel plate and a press, install a new dust cover.
NOTICE: Be careful not to damage the dust cover.
81. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY (W/O TORQUE SENSING LSD)
a. Install the 2 side gear shafts to the differential case.
b. Using needle nose pliers, install 2 new snap rings to the 2 side gear shafts.
c. Using vernier calipers, measure the distance between the right and left side gear shafts, as shown in the illustration.
Standard distance: 242 mm (9.528 inch) or less
82. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY (W/TORQUE SENSING LSD)
a. Install 2 new snap rings to the side gear shafts.
b. Using SST and 2 nuts, install the 2 side gear shafts until they contact the pinion shaft.
SST 09520-24010 (09520-04010, 09520-32040)
HINT: Check that the shaft is fully inserted by confirming the noise it should make when it is tapped.
83. INSTALL REAR DIFFERENTIAL CARRIER COVER
a. w/Torque sensing LSD: Install the oil deflector and bolt to the carrier cover.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
b. Install the breather plug to the carrier cover.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
c. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.
d. Apply FIPG to the carrier.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent
HINT:
^ FIPG should be applied 2 to 3 mm in diameter with no break.
^ Allow on overlap of 10 mm (0.37 inch) or more between the start and end of FIPG application.
^ Install the carrier cover within 3 minutes after applying FIPG.
^ Do not add oil or drive the vehicle immediately after installing the cover, and leave it as it is for an hour or more. Also, for 12 hours or more, avoid rapid acceleration/deceleration.
e. Install the carrier cover with the 8 bolts.
Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.)
84. INSTALL REAR DIFFERENTIAL MOUNT CUSHION NO. 1
a. Only when the rear differential mount cushion No. 1 is replaced, perform this operation.
b. Using SST, install a new rear differential mount cushion NO. 1.
SST 09316-12010, 09570-24010
NOTICE: Do not set the SST in wrong direction.
85. INSTALL REAR DIFFERENTIAL MOUNT CUSHION NO. 2
a. Only when the rear differential mount cushion NO. 2 is replaced, perform this operation.
b. Using SST, install a new rear differential mount cushion NO. 2
SST 09316-12010, 0957-24010
NOTICE: Do not set the SST in wrong direction.
86. INSTALL DIFFERENTIAL CARRIER ASSY REAR
a. Jack up the differential carrier assy rear and rear suspension member with jack.
b. Install the differential carrier assy rear, dynamic damper to the rear suspension member with 3 bolts.
Torque: 95 Nm (970 kgf-cm, 70 ft. lbs.)
87. INSTALL REAR DIFFERENTIAL SUPPORT NO. 1
a. Install the rear differential support No. 1 and 2 spacers to the rear suspension member with 2 bolts and lock nuts.
Torque: 137 Nm (1,400 kgf-cm, 101 ft. lbs.)
b. Connect the rear differential support No. 1 to the differential carrier with 2 bolts and lock nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
88. INSTALL REAR SUSPENSION MEMBER SUB-ASSY
89. INSTALL REAR DRIVE SHAFT ASSY LH
90. INSTALL REAR DRIVE SHAFT ASSY RH
HINT: Install the RH side by the same procedures with LH side.
91. TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO. 1 LH
92. TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO. 1 RH
HINT: Install the RH side by the same procedures with LH side.
93. TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO. 2 LH
94. TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO. 2 RH
HINT: Install the RH side by the same procedures with LH side.
95. TEMPORARY TIGHTEN STRUT ROD ASSY REAR
96. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY
97. INSTALL REAR DIFFERENTIAL DRAIN PLUG
a. Using a hexagon wrench (10 mm), install the drain plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
98. ADD DIFFERENTIAL OIL
a. Fill the rear differential carrier assy with hypoid gear oil.
Oil grade: Hypoid gear oil API GL-5
Recommended oil viscosity:
Above -18°C (0°F) SAE 90
Below -18°C (0°F) SAE 80W or 80W-90
Capacity: 0.9 ± 0.05 liters (0.95 ± 0.05 US qts., 0.79 ± 0.04 Imp. qts.)
99. INSPECT DIFFERENTIAL OIL
100. INSTALL REAR DIFFERENTIAL FILLER PLUG
a. Using a hexagon wrench (10 mm), install the filler plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.
101. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
102. STABILIZE THE SUSPENSION
103. FULLY TIGHTEN STRUT ROD ASSY REAR
104. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO. 1 LH
105. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO. 1 RH
HINT: Install the RH side by the same procedures with LH side.
106. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO. 2 LH
107. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO. 2 RH
HINT: Install the RH side by the same procedures with LH side.
108. INSTALL EXHAUST PIPE ASSEMBLY
109. CHECK EXHAUST GAS LEAK
110. CHECK ABS SPEED SENSOR SIGNAL