Front Differential

Part 1 Of 2:

Part 2 Of 2:

OVERHAUL
1. REMOVE FRONT WHEELS
2. REMOVE ENGINE UNDER COVER ASSY REAR
a. Remove the 6 bolts and engine under cover assy rear.
3. REMOVE ENGINE UNDER COVER SUB-ASSY No.1
a. Remove the 4 bolts and engine under cover sub-assy No.1.
4. DRAIN DIFFERENTIAL OIL
5. REMOVE PROPELLER SHAFT ASSY FRONT
6. REMOVE FRONT AXLE HUB LH NUT
7. REMOVE FRONT AXLE HUB RH NUT
8. SEPARATE FRONT STABILIZER LINK ASSY LH
9. SEPARATE FRONT STABILIZER LINK ASSY RH
10. SEPARATE SPEED SENSOR FRONT LH
11. SEPARATE SPEED SENSOR FRONT RH
12. SEPARATE TIE ROD END SUB-ASSY LH
SST 09628-62011
13. SEPARATE TIE ROD END SUB-ASSY RH
SST 09628-62011
14. REMOVE FRONT SUSPENSION ARM SUB-ASSY LOWER No.1 LH
15. REMOVE FRONT SUSPENSION ARM SUB-ASSY LOWER No.1 RH
16. REMOVE FRONT DRIVE SHAFT ASSY LH
17. REMOVE FRONT DRIVE SHAFT ASSY RH





18. REMOVE DIFFERENTIAL CARRIER ASSY FRONT
a. Remove the bolt and separate the front differential breather tube bracket.
b. Support the front differential with a jack.
c. Remove the front differential mount nut No.1.
d. Remove the 2 front mounting bolts and 2 nuts.
e. Lower the jack and remove the front differential assembly.
f. Remove the 2 bolts and front differential support No.3.
g. Remove the 5 bolts and 2 front differential supports"





19. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION
a. Using SST and a dial indicator, measure the ring gear backlash
SST 09564-32011
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 of backlash between the drive pinion and ring gear 0.49 - 0.78 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
21. 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 0.25 - 0.45 Nm (2.5 - 4.6 kgf-cm, 2.2 - 4.0 inch lbs.)
If necessary. disassemble and inspect the differential.





22. REMOVE FRONT DIFFERENTIAL TUBE ASSY
a. Remove the 4 bolts.
b. Using a plastic hammer, remove the differential tube.





23. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST, remove the oil seal.
SST 09308-00010





24. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSY FRONT
a. Using SST and a hammer, unstake the nut.
SST 09930-00010





b. Using SST to hold the companion flange remove the nut.
SST 09330-00021 (09330-00080)





c. Using SST, remove the companion flange.
SST 03950-30012 (09951-03010, 09953-03010, 09954-03100, 09955-03030, 09956-030203





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





27. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST, remove the rear bearing from the drive pinion.
SST 09556-22010
b. Remove the bearing spacer.
28. REMOVE DIFFERENTIAL SIDE BEWARING RETAINER
a. Using a screwdriver, remove the pinion
b. Remove the 15 bolts and tap out the side bearing retainer with a plastic Hammer.
29. REMOVE DIFFERENTIAL CASE ASSY
30. REMOVE DIFFERENTIAL DRIVE PINION





31. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST and a press, remove the front bearing and washer from the drive pinion.
SST 09950-00020

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





32. REMOVE FRONT BEARING OUTER RACE
a. Using a brass bar and a hammer, remove the front bearing outer race.





33. REMOVE REAR BEARING OUTER RACE
a. Using SST, remove the rear bearing outer race.
SST 09502-12010, 09612-65014 (09612-0102O, 09612-01050)
b. Using a brass bar and a hammer, remove the oil storage ring.





34. REMOVE SIDE BEARING OUTER RACE

HINT:
^ Measure the plate washer and note the thickness.
^ Tag the bearing outer races to show the location for reassembly.

a. Using SST and a press, remove the outer race and plate washer from the bearing retainer.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)





b. Using SST and a press, remove the outer race and plate washer from the differential carrier assy.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)
35. REMOVE DIFFERENTIAL RING GEAR
a. Place matchmarks on the ring gear and differential case assy.
b. Remove the 10 bolts.
c. Using a plastic hammer, tap on the ring gear to separate it from the differential case assy.





36. REMOVE FRONT DIFFERENTIAL CASE BEARING
a. Using SST, remove the 2 differential case bearings from the differential case assy.
SST 09950-60010 (09951-00390), 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)

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





37. DISASSEMBLE DIFFERENTIAL CASE
a. Using a pin punch and a hammer, remove the straight pin.
b. Remove there's part from the differential case assy.
1. Differential side gear (2 pieces)
2. Differential side gear thrust washer (2 pieces)
3. Differential pinion shaft
4. Differential pinion gear (2 pieces)
5. Differential pinion gear thrust washer (2 pieces)
38. INSPECT DIFFERENTIAL GEAR KIT
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 gear kit.
39. INSPECT FRONT DIFFERENTIAL CASE
a. Check that no damaged is differential case assy.
If the differential case assy is damaged, replace the differential case assy.





40. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST, remove the oil seal from the differential tube.
SST 0930-00010





41. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY RH
a. Using a snap ring expander, remove the snap ring.
b. Remove the side gear shaft from the differential tube.





42. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING
a. Using a snap ring expander, remove the snap ring.
b. Using SST, a brass bar and a press, remove the bearing.
SST 09950-00020

NOTICE: Do not damage the bearing.





43. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR
a. Using SST, a socket wrench and a press, remove the dust deflector SST 09950-00020





44. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR
a. Using a steel plate and a press, install a new dust deflector.

NOTICE: Do not damage the dust deflector.





45. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING
a. Using SST and a press, install the bearing.
SST 09226-00010
b. Using a snap ring expander, install the snap ring.





46. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY RH
a. Install the side gear shaft into the differential tube.
b. Using snap ring pliers, install the snap ring.





47. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST and a plastic hammer, install a new oil seal.
SST 09608-32010
Oil seal drive in depth: 5.3 - 0.5 mm (0.2087 - 0.0197 inch)
b. Coat the oil seal lip with MP grease.





48. INSTALL FRONT DIFFERENTIAL CASE
a. Install the 2 proper thrust washers on the 2 side gears.

HINT: Using the table, select thrust washer which will ensure that the backlash is within the specifications.





Washer thickness

b. Install the 2 side gears, 2 side gear thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft in the differential case assy.

HINT: Align the holes of the differential case assy and pinion shaft.

c. Measure the side gear backlash.





1. Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the differential case assy.
Backlash: 0 - 0.15 mm (0 - 0.00591 inch)
If the backlash is not within the specification, install side gear thrust washer with different thicknesses.





d. Using a pin punch and hammer, install the straight pin through the differential case assy and hole of the pinion shaft.
e. Stake the differential case assy.





49. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case assy and ring gear.
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 assy.

HINT: Align the matchmarks on the ring gear and differential case assy.

e. Temporarily install 5 new lock plates and 10 bolts so that the bolt holes in the ring gear and differential case assy are not misaligned.
f. After the ring gear has cooled sufficiently, torque the ring gear set bolts.
Torque: 97 Nm (985 kgf-cm, 71 ft. lbs.)





50. INSTALL FRONT DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the 2 differential case bearings into the differential case assy.
SST 09226-10010
51. INSTALL SIDE BEARING OUTER RACE

HINT: When replacing the 2 differential case bearings, fit 2 new thinnest washers to each bearing and when reusing the bearings, fit the thickness washers with the same thickness as removed.

a. Install a new plate washer to the side bearing retainer.





b. Using SST and a press, install the bearing outer race to the differential case bearing retainer assy.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07150)
c. Install a new plate washer to the differential carrier assy.





d. Using SST and a press, install the bearing outer race to the differential carrier assy.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07150)





52. INSTALL FRONT BEARING OUTER RACE
a. Using SST, install the outer race.
SST 09950-00020 (09951-00680, 09951-00890)
53. INSTALL REAR BEARING OUTER RACE
a. Install the oil stage ring.
b. Using SST, install the outer race.
SST 09950-00020 (09951-00680, 09951-00890)
54. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Install the washer on the drive pinion.

HINT: First fit a washer with the same thickness with the removed washer, then after checking the tooth contact pattern, replace the washer with one of a differential thickness if necessary.





b. Using SST and a press, install the front bearing onto the drive pinion.
SST 09506-30012
55. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Install the drive pinion.

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





b. Using SST, install the rear bearing, oil slinger and companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09956-83010, 09955-03030, 09956-03020)
c. Coat the threads of the nut with hypoid gear oil.





d. Adjust the drive pinion preload by tightening the companion flange nut.
e. Using SST to hold the companion flange, tighten the nut.
SST 09330-00021 (09330-00030)

NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.





f. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.
Preload (at starting)
New bearing: 0.98 - 1.57 Nm (10 - 16 kgf-cm, 8.7 - 13.9 inch lbs.)
Reused bearing: 0.49 - 0.78 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
56. INSTALL DIFFERENTIAL CASE ASSY
57. ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION
a. Install the side bearing retainer with the 10 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)





b. Using SST and a dial indicator, measure the ring gear backlash.
SST 09564-32011
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
c. If it is not within the specification, adjust it by either increasing or decreasing the washers on both sides by an equal amount.

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





Washer thickness





58. 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 0.25 - 0.45 Nm (2.5 - 4.6 kgf-cm, 2.2 - 4.0 inch lbs.)
If necessary, disassemble and inspect the differential.
59. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Remove the side bearing retainer and differential case assy.





b. Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead.
c. Install the differential case assy and side bearing retainer.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
d. Hold the companion flange firmly and rotate the ring gear in both directions.
e. Remove the differential case and side bearing retainer and differential case assy.





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

g. Remove the companion flange and oil slinger.
SST 09330-00021 (09330-00030), 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
h. Remove the rear bearing.
60. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install a new bearing spacer and oil stage ring.
61. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
62. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
63. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSY FRONT
a. Place the companion flange on the drive pinion.
b. Coat the threads of a new nut with hypoid gear oil LSD.





c. Using SST and the companion flange, install the rear tapered roller bearing, then remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)





64. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL
a. Using SST and a hammer, install the oil seal.
SST 09330-0021 (0933-00030), 09550-22010
Oil seal drive in depth: 4.35 - 0.45 mm (0.171 - 0.018 inch)
b. Coat the oil seal lip with MP grease.





c. Using SST to hold the flange, torque the nut.
Torque: 370 Nm (3,770 kgf-cm, 37 ft. lbs.)





65. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
a. Remove the 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 to the side bearing retainer, as shown.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

HINT: Install the side bearing retainer within 10 minutes after applying FIPG.

d. Install the side bearing retainer with the 10 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
e. Install a union.





66. 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: 0.98 - 1.57 Nm (10 - 16 kgf-cm, 8.7 - 13.9 inch lbs.)
Reused bearing: 0.49 - 0.78 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
If the preload is greater than the specification, replace the bearing spacer.
If the preload is less than the specification, retighten the nut 13 Nm (130 kgf-cm, 9 ft. lbs.) a little at a time until the specified preload is reached.
Torque: 370 Nm (3,773 kgf-cm, 268 ft. lbs.) or less
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repair the preload procedure. Do not back off the nut to reduce the preload.
67. INSPECT TOTAL PRELOAD
68. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION
69. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSY FRONT
70. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT NUT





71. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST and a plastic hammer, install a new oil seal until its surface is flush with the differential carrier end.
SST 09608-32010
b. Coat the oil seal lip with MP grease.





72. INSTALL FRONT DIFFERENTIAL TUBE ASSY
a. Remove the any oil 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 to the differential, as shown.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

HINT: Install the differential tube within 10 minutes after applying FIPG.

d. install the differential tube to the differential carrier assy.





e. Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
f. Apply adhesive to 2 to 3 threads of the bolts end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
g. Install the 4 bolts.
Torque: 110 Nm (1,122 kgf-cm, 81 ft. lbs.) or less





73. INSTALL DIFFERENTIAL CARRIER ASSY FRONT
a. Install the 2 mounting supports with the 5 bolts.
Torque: 186 Nm (1,897 kgf-cm, 137 ft. lbs.)
b. Install the front differential support No.3 with the 2 bolts.
Torque: 108 Nm (1,101 kgf-cm, 80 ft. lbs.)
c. Support the front differential with a jack.
d. Install the 2 front mounting bolts and nuts.
Torque: 137 Nm (1,397 kgf-cm, 101 ft. lbs.)
e. Install the front differential mount nut No.1.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)
f. Install the front differential breather tube bracket with a bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
h. Lower the jack.
74. INSTALL FRONT DRIVE SHAFT ASSY LH
75. INSTALL FRONT DRIVE SHAFT ASSY RH
76. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER No.1 LH
77. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER No.1 RH
78. INSTALL TIE ROD END SUB-ASSY LH
79. INSTALL TIE ROD END SUB-ASSY RH
80. INSTALL SPEED SENSOR FRONT LH
81. INSTALL SPEED SENSOR FRONT RH
82. INSTALL FRONT STABILIZER LINK ASSY LH
83. INSTALL FRONT STABILIZER LINK ASSY RH
84. INSTALL FRONT AXLE HUB LH NUT
85. INSTALL FRONT AXLE HUB RH NUT
86. INSTALL PROPELLER SHAFT ASSY FRONT
87. FILL UP DIFFERENTIAL OIL
88. INSPECT DIFFERENTIAL OIL
89. INSTALL ENGINE UNDER COVER SUB-ASSY No.1
a. Install the engine under cover sub-assy No.1 with the 4 bolts.
90. INSTALL ENGINE UNDER COVER ASSY REAR
a. Install the engine under cover assy rear with the 6 bolts.
91. INSTALL FRONT WHEEL
Torque: 112 Nm (1,142 kgf-cm, 83 ft. lbs.)
92. CHECK ABS SPEED SENSOR SIGNAL