Disassembly and Assembly
DISASSEMBLY1. REMOVE DIFFERENTIAL CARRIER COVER
a. Remove the 8 bolts from the carrier cover.
b. Using a brass bar and hammer, separate the cover from carrier.
c. Remove the breather plug from the differential carrier cover.
d. Remove the bolt and oil deflector from the differential carrier cover.
2. CHECK RUNOUT OF COMPANION FLANGE
Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
Maximum runout: 0.10 mm (0.0039 inch)
3. CHECK RING GEAR RUNOUT
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.
4. CHECK RING GEAR BACKLASH
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.
5. CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
6. 2 PINION DIFFERENTIAL: CHECK SIDE GEAR BACKLASH
Using a dial indicator, check the backlash of the side gear while holding 1 pinion gear toward the differential case.
Backlash: 0.05-0.20 mm (0.0020-0.0079 inch)
If the backlash is not within the specification, install the 2 side gear thrust washers of different thickness.
7. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting): 0.6-0.9 Nm (6-9 kgf-cm, 5.2-7.8 inch lbs.)
8. CHECK TOTAL PRELOAD
Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus 0.3-0.5 Nm (3-5 kgf-cm, 2.6-4.3 inch lbs.)
If necessary, disassemble and inspect the differential.
9. TORQUE SENSING LSD: REMOVE SIDE GEAR SHAFTS
a. Using SST, remove the 2 side gear shafts from the differential.
SST 09520-24010 (09520-04010, 09520-32040)
b. Using a screwdriver, remove the 2 snap rings from the 2 side gear shafts.
10. 2 PINION DIFFERENTIAL: REMOVE SIDE GEAR SHAFTS
a. Using needle nose pliers, remove the 2 snap rings from the 2 side gear shafts.
b. Remove the 2 side gear shafts.
11. REMOVE SIDE GEAR SHAFT OIL SEALS
Using SST, remove the 2 oil seals from the housing.
SST 09308-00010
12. REMOVE COMPANION FLANGE
a. Using a chisel and hammer, unstake the staked part of nut.
b. Using SST to hold the flange, remove the nut.
SST 0933G-00021
c. Using SST, remove the companion flange.
SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
13. REMOVE FRONT OIL SEAL AND OIL SLINGER
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
b. Remove the oil slinger.
14. REMOVE FRONT BEARING AND BEARING SPACER
a. Using SST, remove the front bearing from the drive pinion.
SST 09556-22010
b. Remove the bearing spacer.
15. REMOVE DIFFERENTIAL CASE ASSEMBLY
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 4 bolts and 2 bearing caps.
c. Using SST and a hammer, remove the 2 plate washers.
SST 09504-22011
HINT: Measure the plate washer and note down the thickness.
d. Remove the differential case assembly and 2 bearing outer races from the differential carrier.
HINT: Tag the 2 bearing outer races to show the location for reassembling.
16. REMOVE DRIVE PINION FROM DIFFERENTIAL CARRIER
17. REMOVE DRIVE PINION REAR 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.
b. Remove the plate washer.
18. REMOVE FRONT AND REAR BEARING OUTER RACES
Using a brass bar and hammer, remove the 2 outer races from the carrier.
19. REMOVE RING GEAR
a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver and hammer, unstake the 4 lock plates.
c. Remove the 8 ring gear set bolts and 4 lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
20. REMOVE SIDE BEARINGS Using SST and a press, remove the 2 side bearings from the differential case.
SST 09950-00020
NOTICE: Be careful not to drop the differential case.
21. 2 PINION DIFFERENTIAL: DISASSEMBLE DIFFERENTIAL CASE
NOTICE: If equipped with torque sensing LSD, do not disassemble the differential case.
a. Using a pin punch and hammer, remove the straight pin.
b. Remove the pinion shaft.
c. Remove the 2 pinion gears.
d. Remove the 2 pinion gear thrust washers.
e. Remove the 2 side gears.
f. Remove the 2 side gear thrust washers.
REPLACEMENT
1. REPLACE COMPANION FLANGE DUST DEFLECTOR IF NECESSARY
a. Using SST and a press, remove the dust deflector.
SST 09950-00020
b. Using a press, install a new dust deflector.
2. REPLACE SIDE GEAR SHAFT DUST COVER, IF NECESSARY
a. Using a screwdriver and hammer, remove the side gear shaft dust cover.
b. Using a steel plate and press, install a new dust cover to the side gear shaft.
NOTICE: Be careful not to damage the dust cover.
REASSEMBLY
1. 2 PINION DIFFERENTIAL: REASSEMBLE DIFFERENTIAL CASE
a. Install the 2 thrust washers on the 2 side gears.
b. Install the 2 side gears, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft in the differential case.
HINT: Align the holes of the differential case and pinion shaft.
c. Measure the side gear backlash while holding 1 pinion gear toward the differential case.
Backlash: 0.05-0.20 mm (0.0020-0.0079 inch)
If the backlash is not within the specification, install the 2 side gear thrust washers with different thicknesses.
HINT: Refer to the table to select 2 thrust washers which will ensure that the backlash is within the specification.
d. Using a pin punch and hammer, install the straight pin through the differential case and hole of the pinion shaft.
e. Using a chisel and hammer, stake the outside of the differential case pin hole.
2. INSTALL RING GEAR ON DIFFERENTIAL CASE
a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear to 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.
f. Temporarily install the 4 new lock plates and 8 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.)
h. Using a chisel and hammer, stake the 4 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.
3. INSTALL SIDE BEARINGS
Using SST and a press, install the 2 side bearings into the differential case.
SST 09710-22021 (09710-01031)
4. INSPECT RING GEAR RUNOUT
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 bearing caps.
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.
5. INSTALL FRONT AND REAR BEARING OUTER RACES
a. Front side:
Using SST and a press, install the outer race to the carrier.
SST 09950-60020 (09951-00790), 09950-70010 (09951-07150)
b. Rear side:
Using SST and a press, install the outer race to the carrier.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
6. INSTALL DRIVE PINION REAR 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
7. TEMPORARILY ADJUST DRIVE PINION PRELOAD
a. Install the drive pinion and front bearing.
HINT: Assemble the spacer, oil slinger and oil seal after adjusting the gear contact pattern.
b. Using SST, install the companion flange.
SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
c. Coat the threads of the nut with MP grease.
d. Adjusting the drive pinion preload by tightening the companion flange nut.
Using SST to hold the flange, torque the nut.
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
SST 09330-00021
NOTICE: As there is no spacer, torque a little at a time, being careful not to overtighten it.
e. Using a torque wrench, measure the preload.
Preload (at starting):
New bearing: 1.1-1.7 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.)
8. INSTALL DIFFERENTIAL CASE IN CARRIER
a. Place the 2 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. Install only the plate washer on the ring gear back side.
b. Snug down the washer and bearing by tapping on the ring gear with a plastic hammer.
c. Using a dial indicator, hold the companion flange and measure the ring gear backlash.
Backlash (reference): 0.13 mm (0.0051 inch)
d. Select a ring gear back side plate washer so that the backlash is 0.13 mm (0.0051 inch).
e. Select a ring gear teeth side washer so that there is no clearance between the outer race and case.
f. Remove the plate washer and differential case.
g. Install the plate washer to the ring gear back side.
h. Place the outer plate washer onto the differential case together with the outer race, and install the differential case with the outer race into the carrier.
i. Using a plastic hammer, snug down the washer and bearing by tapping the ring gear.
j. Using a dial indicator, hold the companion flange and measure the ring gear backlash.
Backlash: 0.13-0.18 mm (0.0051-0.0071 inch)
If it is not within the specification, adjust it by either increasing or decreasing the thickness of washers on both sides by an equal amount.
HINT: There should be clearance between the plate washer and case. Ensure that there is ring gear backlash.
10. ADJUST SIDE BEARING PRELOAD
a. After adjusting the ring gear backlash as reference, remove the teeth side plate washer.
b. Using a micrometer, measure the thickness of the removed plate washer.
c. Install a new washer 0.06-0.09 mm (0.0024-0.0035 inch) thicker than the removed washer.
HINT: Select a washer which can be pressed in 2/3 of the way by finger.
d. Using SST and a hammer, tap in the plate washer.
SST 09504-22011
e. Align the matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps and 4 bolts.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.)
f. Recheck the ring gear backlash.
Backlash: 0.13-0.18 mm (0.0051-0.0071 inch)
If it is not within the specification, adjust it by either increasing or decreasing the washers thickness on both sides by equal amount.
HINT: The backlash will change by about 0.02 mm (0.0008 inch) corresponding to 0.03 mm (0.0012 inch) change in the plate washer thickness.
WASHER THICKNESS
11. MEASURE TOTAL PRELOAD
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 ft. lbs.)
12. 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
13. REMOVE COMPANION FLANGE
14. REMOVE FRONT BEARING
15. INSTALL NEW BEARING SPACER AND FRO, BEARING
Install a new bearing spacer and front bearing on the drive pinion.
16. INSTALL OIL SLINGER
17. INSTALL NEW FRONT OIL SEAL
a. Using SST and hammer, install a new oil seal.
SST 09554-22010
Oil seal drive in depth: 2.0 mm (0.079 inch)
b. Coat MP grease to the oil seal lip.
18. INSTALL COMPANION FLANGE
a. Using SST, install the companion flange on the drive pinion.
SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
b. Coat the threads of a new nut with hypoid gear oil.
c. Using SST to hold the flange, torque the nut.
SST 09330-00021
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
19. CHECK 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: 1.1-1.7 Nm (11-17 kgf-cm, 9.6-14.8 ft. 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.
20. RECHECK TOTAL PRELOAD (See step 11)
21. RECHECK RING GEAR BACKLASH (See step 9)
22. RECHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See step 12)
23. CHECK COMPANION FLANGE RUNOUT
24. STAKE DRIVE PINION NUT
25. INSTALL SIDE GEAR SHAFT OIL SEALS
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 (09951-07150)
b. Coat MP grease to the oil seal lip.
26. TORQUE SENSING LSD: INSTALL SIDE GEAR SHAFTS
a. Install 2 new snap rings to the side gear shafts.
b. Using SST, 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.
27. 2 PINION DIFFERENTIAL: INSTALL SIDE GEAR SHAFTS
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.
28. INSTALL DIFFERENTIAL CARRIER COVER
a. Install the oil deflector and bolt to the carrier cover.
Torque: 7.4 Nm (75 kgf-cm, 65 ft. 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: Install the carrier cover within 3 minutes after applying FIPG.
e. Torque the 8 bolts.
Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.)