Rear Differential

Part 1 Of 2:

Part 2 Of 2:

OVERHAUL
1. REMOVE REAR WHEEL
2. SEPARATE PROPELLER SHAFT ASSY
3. DRAIN DIFFERENTIAL OIL
4. SEPARATE SPEED SENSOR REAR LH
5. SEPARATE SPEED SENSOR REAR RH
6. SEPARATE REAR DISC BRAKE CALIPER ASSY LH
7. SEPARATE REAR DISC BRAKE CALIPER ASSY RH
8. REMOVE REAR DISC
9. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING
10. REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING
11. REMOVE PARKING BRAKE SHOE STRUT LH
12. REMOVE PARKING BRAKE SHOE
13. REMOVE REAR AXLE SHAFT W/BACKING PLATE





14. REMOVE DIFFERENTIAL CARRIER ASSY REAR
a. Remove the 10 nuts, 10 washers and differential carrier assy.

NOTICE: Be careful not to damage the removal surface.

15. REMOVE REAR DIFFERENTIAL CARRIER GASKET
16. FIX DIFFERENTIAL CARRIER ASSY REAR





17. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using a dial indicator, measure the vertical and lateral runout of the companion flange
Maximum runout:
Vertical runout: 0.1 mm (0.0039 inch)
Lateral runout: 0.1 mm (0.0039 inch)
If the runout are not within the specification, replace the companion flange





18. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
a. Using a dial indicator, check the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
If the runout is greater than the maximum, replace the ring gear with new one.





19. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using a dial indicator, check the backlash of the ring gear.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.





20. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload.
Preload (at starting): 0.56 - 0.85 Nm (5.7 - 8.7 kgf-cm, 5.0 - 7.5 inch lbs.)

HINT: Before measurement, rotate the ring gear 5 time or more.

21. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the total preload with the teeth of the drive pinion and ring rear in contact.
Total preload (at starting):
Drive pinion preload plus 0.39 - 0.59 Nm (4.0 - 6.0 kgf-cm, 3.5 - 5.2 inch lbs.)
If necessary, disassemble and inspect the differential.





22. REMOVE REAR DRIVE PINION NUT
a. 2WD drive type: Using a torx socket (E10), remove the 4 stud bolts.
b. Using SST and a hammer, unstake the nut.
SST 09930-00010





c. Using SST to hold the companion flange, remove the nut.
SST 09330-00021 (09330-00030)





23. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)





24. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
25. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER





26. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST, remove the front bearing from the drive pinion.
SST 09556-22010





27. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK
a. Remove the 2 bolts and 2 adjusting nut locks.





28. REMOVE DIFFERENTIAL CASE ASSY
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 4 bolts and 2 bearing caps.
c. Remove the 2 adjusting nuts.





d. Remove the rear differential case assy and 2 bearing outer races from the differential carrier assy.

HINT: Tag the 2 bearing outer races to show the location for reassembling.





29. REMOVE DIFFERENTIAL DRIVE PINION
a. Remove the drive pinion from the differential carrier assy.
b. Remove the bearing spacer.





30. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, remove the rear bearing from the drive pinion.
SST 09950-00020

HINT: If the drive pinion or ring gear are damaged, replace them as a set.

31. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER
a. Remove the plate washer from the drive pinion.





32. REMOVE FRONT BEARING OUTER RACE
a. Using a brass bar and a hammer, remove the front bearing outer race from the differential carrier assy.
33. REMOVE DIFFERENTIAL OIL STORAGE RING
a. Using a brass bar and a hammer, remove the oil storage ring.





34. REMOVE REAR BEARING OUTER RACE
a. Using a brass bar and a hammer, remove the rear bearing outer race from the differential carrier assy.





35. REMOVE DIFFERENTIAL RING GEAR
a. Place matchmarks on the ring gear and differential case assy.
b. Using a screwdriver and a hammer, unstake the 5 lock plates.
c. Remove the 10 ring gear set bolts and 5 lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case assy.





36. INSPECT DIFFERENTIAL CASE ASSY RUNOUT

HINT: It will be done only when it exceeds the limit at the ring gear runout check.

a. Install the differential case assy to the differential carrier assy.
b. Align the matchmarks, install the 2 bearing caps with the 4 bolts to the differential carrier assy.
Torque: 85 Nm (867 ft. lbs., 63 ft. lbs.)
c. Inspect the differential case runout.
Maximum runout: 0.07 mm (0.0028 inch)
d. Remove the 4 bolts and bearing caps for tire differential carrier assy.
e. Remove the differential case assy from the differential carrier assy.





37. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the rear 2 differential case bearings from the differential case assy.
SST 09950-40011 (09951-04010, 09952-0401O, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-0480), 09950-60020 (09951-0730)

HINT: Fix the claws of SST to the notches in the differential case assy.





38. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, remove the dust deflector.
SST 09950-60010 (09951-00380), 09950-70010 (09951-07150), 09950-00020





39. DISASSEMBLE DIFFERENTIAL CASE
a. Place matchmarks on the LH and RH cases.
b. Remove the 8 bolts uniformly, a little at a time.
c. Using a plastic hammer, separate the LH and RH cases.





d. Remove three parts from the differential case assy.
1. Differential side gear (2 pieces)
2. Differential side gear thrust washer (2 pieces)
3. Differential spider
4. Differential pinion (4 pieces)
5. Differential pinion thrust washer (4 pieces)
40. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
a. Check that no damage is identified on the pinion gear and side gear. If the pinion gear and/or side gear is damaged, replace the differential.
41. INSPECT DIFFERENTIAL CASE
a. Check that no damaged is differential case assy. If the differential case assy is damaged, replace the differential case assy.





42. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST, a press and a steel plate, install the dust deflector.
SST 09636-20010

NOTICE: Be careful not to damage the dust deflector.





43. INSTALL DIFFERENTIAL CASE ASSY
a. Install the differential side gear thrust washer to the differential side gear.
b. Install the 4 differential pinion thrust washers and 4 differential pinion gears to the differential spider.
c. Fix the differential case RH.





d. Install the differential side gear and differential spider to the differential case RH.





e. Using a dial indicator, measure the differential case RH side backlash while holding pinion toward the case.
Backlash: 0.05 - 0.20 mm (0.002 - 0.008 inch)
f. Remove the differential spider from the differential case RH.





g. Install the differential side gear and differential spider to the differential case LH.
h. Using a dial indicator, measure the differential case LH side backlash while holding pinion toward the case.

HINT: Measure E all 4 locations.

Backlash: 0.05 - 0.20 mm (0.002 - 0.008 inch)
If the backlash is not within the specification, install the 2 side gear thrust washers with different thickness.





Thrust washer thickness





i. Install the differential side gear thrust washer to the RH case.
j. Install the differential pinion gears and differential spider to the RH case.
k. Install the differential side gear and differential side gear thrust washer to the RH case.





l. Align the matchmarks and assemble the RH and LH cases.
m. Using a plastic hammer, install the RH and LH cases.
n. Install the 8 bolts.
Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)





44. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the 2 differential case bearings on the differential case assy.
SST 09223-15020, 09950-60010 (09951-00480, 09951-00550), 09950-60020 (09951-00730)





45. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case assy and ring gear.
b. Heat the ring gear approx. 100°C (212°F) in the boiling water.
c. Carefully take the ring gear out of 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 assy.
f. Temporarily install 5 new lock plates and 10 set bolts.
g. After the ring gear cools down enough, torque the 8 bolts uniformly at a time.
Torque: 97 Nm (985 kgf-cm, 71 ft. lbs.)

HINT: Tighten the bolts in diagonal order little by little over several times.






h. Using a chisel and a hammer, stake the 5 lock plates.

HINT: Stake one claw so that it is 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.






46. INSPECT DIFFERENTIAL RING GEAR RUNOUT
a. Install the differential case on the carrier, and install the 2 adjusting nut so that there is no play in the bearing.
b. Install the 2 bearing caps with the 4 bolts.
Torque: 85 Nm (867 kgf-cm, 63 ft. lbs.)
c. Install 2 adjusting nut locks with the 2 bolts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
d. Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
If it is not within the specification, replace the ring gear.
e. Remove the 2 bolts and adjusting nut locks.
f. Remove the 2 bearing caps, 2 adjusting nuts and differential case assy.





47. INSTALL FRONT BEARING OUTER RACE
a. Using a brass bar and a hammer, install a new oil storage ring.
b. Using SST and a hammer, install the front bearing outer race to the differential carrier assy.
SST 09316-60011 (09316-00011, 09316-00021)





48. INSTALL REAR BEARING OUTER RACE
a. Using SST and a press, install the rear bearing outer race to the differential carrier case.
SST 09316-60011 (09316-00011, 09316-00051)





49. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Install the plate washer on the drive pinion.
b. Using SST and a press, install the rear bearing onto the drive pinion.
SST 09506-30012





50. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Install the drive pinion, front bearing and oil slinger.

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





b. Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09950-03010, 09955-03030, 09956-03030)
c. Coat the threads of the nut with hypoid gear oil LSD.





d. Using SST to hold the companion flange, torque the nut.
SST 09330-00021
Torque: 215 Nm (2,190 kgf-cm, 159 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.





e. Using a torque wrench, measure the preload of backlash between the drive pinion gear and ring gear.
Preload (at starting):
New bearing: 1.05 - 1.64 Nm (10.7 - 16.7 kgf-cm, 9.3 - 14.5 inch lbs.)
Reused bearing: 0.56 - 0.85 Nm (5.7 - 8.7 kgf-cm, 5.0 - 7.5 inch lbs.)

HINT: Measure the total preload after first turning the bearing clock wise and counterclockwise several times to make the bearing smooth.





51. INSTALL REAR DIFFERENTIAL CASE SUB-ASSY
a. Place the 2 bearing outer races on their respective bearings.
b. Install the differential case assy in the differential carrier assy.

HINT:
^ Make sure the right and left outer races are not interchanged.
^ Make sure that there is a backlash between the ring rear and drive pinion.





52. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT
a. Install the rear differential bearing adjusting nuts on the carrier, making sure the nuts are threaded properly.





53. ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION
a. Align the matchmarks on the bearing cap and differential carrier assy.
b. Install the 2 bearing caps with the 4 bolts.
Torque: 85 Nm (867 kgf-cm, 63 ft. lbs.)

HINT: If the bearing cap does fit tightly on the differential carrier assy, the adjusting nuts are not threaded properly. Reinstall the adjusting nuts if necessary.





c. Torque the 4 bearing cap bolts to the specified torque, then loosen them to the point where the adjusting nuts can be turned by SST.
SST 09504-00011





d. Using the SST, torque the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008 inch).
SST 09500-00011





e. While turning the ring gear, use the SST to fully tighten the adjusting nut on the drive pinion side.
After the bearings as settled, loosen the adjusting nut on the drive pinion side.
f. Using SST, torque the adjusting nut 1 - 1.5 notches from the 0 preload position.
SST 09500-00011





g. Using a dial indicator, adjust the ring gear backlash until it is within the specification.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
SST 09504-00011

HINT: The backlash is adjusted by turning the left and right adjusting nuts for an equal amounts. For example, loosen the nut on the right side one notch.





h. Torque the 4 bearing cap bolts.
Torque: 85 Nm (867 kgf-cm, 63 ft. lbs.)





54. INSPECT TOTAL PRELOAD
a. 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 0.39 - 0.59 Nm (4.0 - 6.0 kgf-cm, 3.5 - 5.2 inch lbs.)
If necessary, disassemble and inspect the differential.





55. 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.
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 chart to select a Droner washer for correction.
56. REMOVE REAR DRIVE PINION NUT
SST 09330-00021
57. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)
58. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
59. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
SST 09556-22010
60. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
61. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
62. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER





63. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST and a hammer, install a new oil seal.
SST 09554-30011
Oil seal drive in depth: 1.0 - 0.45 mm (0.039 - 0.018 inch)
b. Coat the oil seal lip with the MP grease.





64. 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, 09954-03010, 09955-03030, 09956-03030), 09330-00021
b. Coat the threads of a new nut with hypoid gear oil LSD.





c. Using SST to hold the companion flange, torque the nut.
SST 09330-00021
Torque: 215 Nm (2.190 kgf-cm, 159 ft. lbs.)





65. 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: 1.05 - 1.64 Nm (10.7 - 16.7 kgf-cm, 9.3 - 14.5 inch lbs.)
Reused bearing: 0.56 - 0.85 Nm (5.7 - 8.7 kgf-cm, 5.0 - 7.5 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: 370 Nm (3,773 kgf-cm, 26.8 ft. lbs.) or less.
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat lice preload adjusting procedure. Do not loosen the pinion nut to reduce the preload.





66. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus 0.39 - 0.59 Nm (4.0 - 6.0 kgf-cm, 3.5 - 5.2 inch lbs.)
If necessary, disassemble and inspect the differential.





67. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using a dial indicator, check the backlash of the ring gear.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.





68. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
Maximum runout:
Vertical runout: 0.1 mm (0.0039 inch)
Lateral runout: 0.1 mm (0.0039 inch)





69. INSTALL REAR DRIVE PINION NUT
a. Using a chisel and a hammer, stake the nut.
b. 2WD drive type: Using a torx socket (E10), install the 4 stud bolts.
Torque: 10 Nm (101 kgf-cm, 7.3 ft. lbs.)





70. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK
a. Install 2 new rear differential bearing adjusting locks on the bearing caps.
Torque: 13 Nm (133 kgf-cm, 96 ft. lbs.)
b. After tightening 2 bolts, bend the adjusting nut locks.





71. INSTALL DIFFERENTIAL CARRIER ASSY REAR
a. Clean the contact surfaces of the rear differential carrier assy and rear axle housing assy.
b. Install the rear differential carrier assy and a new gasket with the 10 nuts, 10 washers and washers.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
72. INSTALL REAR AXLE SHAFT W/BACKING PLATE
SST 09316-60011 (09316-00051)
73. INSTALL PARKING BRAKE SHOE
74. INSTALL PARKING BRAKE SHOE STRUT LH
75. INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING
76. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING
77. INSTALL REAR DISC
78. CONNECT REAR DISC BRAKE CALIPER ASSY LH
79. CONNECT REAR DISC BRAKE CALIPER ASSY RH
80. CONNECT SPEED SENSOR REAR LH
81. CONNECT SPEED SENSOR REAR RH
82. INSTALL PROPELLER SHAFT ASSY
83. FILL RESERVOIR WITH BRAKE FLUID
84. BLEED MASTER CYLINDER
85. BLEED BRAKE LINE
86. INSPECT BRAKE FLUID LEVEL IN RESERVOIR
87. CHECK BRAKE FLUID LEAKAGE
88. FILL UP DIFFERENTIAL OIL
89. INSPECT DIFFERENTIAL OIL
90. INSTALL REAR WHEEL
Torque: 112 Nm (1,142 kgf-cm, 83 ft. lbs.)
91. INSPECT AND ADJUST PARKING BRAKE LEVER TRAVEL
92. CHECK ABS SPEED SENSOR SIGNAL