Repair Procedures

Replacement

1. Drain the differential gear oil.




2. Remove the rear driveshaft
3. Remove the propellershaft assembly
4. Loosen the differential carrier assembly mount bolts and than remove the differential assembly(A)

Tightening torque Nm (kgf.m, lb-ft) :
80 - 100 (8.0 - 10.0, 57.8 - 72.3)








5. Installation is the reverse order of removal.
6. Check the alignment.

Disassembly

Rear differential carrier
1. Before disassembling Rear differential carrier, drain off oil from Rear differential carrier.





NOTE:
For the first time of oil change, there is a possibility that oil color looks black due to a phosphating wear.

2. Remove the cover bolts.




3. Before disassembling differential case assembly, paint match marks on one side of the bearing cap.




4. Loosen bearing cap bolts and remove bearing caps.




5. Lift differential case assembly out with tool.




6. Keep the side bearing outer races together with inner races.





NOTE:
Do not mix them up.
Also, keep side bearing adjusting washers together with bearings.

Diff assembly Disassembly
1. Remove side bearing inner races. To prevent damage to bearing, engage puller jaws in groove.




2. Be careful not to confuse left- and right-hand parts.




3. Loosen ring gear bolts.
Tap drive gear off the differential case with a soft hammer.
Tap evenly all around to keep drive gear from binding.




4. Drive out pinion mate shaft lock pin with punch from drive gear side.




5. Remove the pinion mate shaft.




6. Remove side gears, pinion mate gears, side gear thrust washers, pinion mate thrust washers from differential case.




Pinion assembly disassembly
1. Loosen the pinion locking nut.




2. Using the press, take out drive pinion (together with pinion rear bearing inner race,pinion bearing adjusting spacer)
Remove companion flange.




3. Using the press, remove pinion rear bearing inner race and pinion height adjusting shim.




4. Using the screwdriver, remove front oil seal.




5. Using the screwdriver, Remove side oil seals.






Inspection

1. Check the tooth contact pattern.






NOTE:
1. Tooth contact pattern is a method for judging the result of the adjustment of drive pinion height and final drive gear backlash. The adjustment of drive pinion height and final drive gear backlash should be repeated until the tooth contact patterns are similar to the standard tooth contact pattern.
2. When you cannot obtain a correct pattern, the drive gear and drive pinion have exceeded their limits. Both gears should be replaced as a set.





Reassembly

Pinion assembly
1. Press-fit pinion front and rear bearing outer races with tools.




2. Install selected pinion height adjusting shim in drive pinion gear.
Using press and tool, press-fit pinion rear bearing inner race into it.




3. Install the pinion bearing adjusting spacer to the drive pinion.





CAUTION:
Pinion bearing adjusting spacer is not reusable.
Never reuse pinion bearing adjusting spacer.

4. Using press and tool, press-fit pinion front bearing inner race.





NOTE:
The pressure do not exceed 5ton.

5. Using press and tool, press-fit front oil seal.




6. Using press and tool, press-fit companion flange.





NOTE:
The pressure do not exceed 5ton.

7. Install the pinion locking nut to make that the bearing free road is standard.

Tightening torque Nm (kgf.m, lb-ft) :
112.7 - 161.8 (11.5 - 16.5, 83.1 - 119.3)




Differential case
1. Fix the diff assembly with both hands and install it to the differential carrier.




2. Insert the left/right diff shim between the diff side bearing and carrier. And then install the bearing cap with marks.




3. Measure drive gear-to-drive pinion backlash with a dial indicator at several point.

Standard:0.10 - 0.15mm





NOTE:
Thickness of the diff shim need to adjusted if backlash is small. Lessen the thickness of the left side diff shim. By contraries enlarge the thickness of the right side diff shim that much.

4. Check total preload with tool.

Standard : Pinion free road : 1.9 - 4.9(0.2 - 0.5, 1.4 - 3.6)




5. Applies liquid sealant to differential carrier as shown in figure




6. Install the differential cover.

Tightening torque Nm (kgf.m, lb-ft) :
39.2 - 49.0 (4.0 - 5.0, 28.9 - 39.1)




7. Using press and tool, press-fit side oil seals.




8. Install the drain plug and filler plug.

Pillar plug: 39.2 - 58.8(4.0 - 5.0, 28.9 - 43.3)
Drain plug: 49.0 - 68.6(5.0 - 7.0, 36.1 - 50.6)




9. Tighten air breather.

Tightening torque Nm (kgf.m, lb-ft) :
9.8 - 19.6 (1.0 - 2.0, 7.2 - 14.4)