Assembly

1. Adjust differential pinion gear backlash.
a. Install the 2 proper thrust washers on the 2 side gears.

HINT: Using the proper washer thickness, select thrust washers which will ensure that the backlash is within the specification. Thrust washer thickness
1.6 mm (0.063 inch)
1.7 mm (0.067 inch)
1.8 mm (0.071 inch)

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. Push the 2 side gear shafts gently into the differential case by hand and install them.





d. Using a dial indicator, measure the pinion gear backlash with holding one side gear toward the 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.
e. Remove the 2 side gear shafts.





2. Install ring gear on differential case.
a. Using a pin punch and hammer, install the straight pin through the differential case and hole of the pinion shaft.
b. Stake the differential case.
3. Install ring gear on differential case.
a. Clean the contact surfaces of the differential case and the threads of the ring gear and differential case.





b. Heat the ring gear 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.





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

e. Tighten 2 of the bolts temporarily so that the bolt holes in the ring gear and differential case are not misaligned.

NOTICE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently.





4. Install ring gear set bolts.
a. After the ring gear has cooled sufficiently, install 10 new ring gear set bolts to which thread lock Part No. 08833 - 00100, THREE BOND 1360 K, or equivalent, has been applied.

NOTICE: New ring gear set bolts should be used in every case.





b. Torque the 10 set bolts uniformly and a little at a time to 64 Nm (47 ft. lbs.)
c. Tighten the bolts an additional 60 - 90°.

NOTICE: Tighten the bolts in diagonally opposite pairs.





5. Install side bearings. Using SST 09710 - 30050, 09550 - 60010 (09951 - 00480), 09950-70010 (09951 -07150) and a press, install the 2 side bearings.

6. Install front and rear bearing outer races and adjusting washer. When removing an adjusting washer, make sure to replace it with a new one.

HINT:
- The adjusting washer is used for adjusting the tooth contact pattern. 42 types of washers with differential thicknesses are available.
- First fit a washer with the same thickness as the washer which was removed, then After checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.





a. Using SST 09527 - 17011, 09950 - 60020 (09951 - 01030), 09950 - 70010 (09951 - 07150) and a press, install a new adjusting washer and rear bearing outer race.

b. Using SST 09950 - 60020 (09951 - 00710), 09950 - 70010 (09951 - 07150) and a press, install the front bearing outer race.





7. Install rear bearing to drive pinion. Using SST 09710 - 30021 (09710 - 03091) and a press, install the rear bearing.
8. Temporarily install drive pinion, front bearing, oil slinger and companion flange
a. install the drive pinion in the differential carrier.





b. Using SST 09223 - 56010, 09316 - 60011 (09316 - 00011) and a press, install the front bearing on the drive pinion.

HINT: Assemble the spacer and oil seal After adjusting the tooth contact pattern.

Fig. 14 Pinion Flange Installation:

c. Install the oil slinger. Using SST 09223 - 56010, 09325 - 40010 and a press, install the companion flange.

9. Temporarily adjust drive pinion preload.
a. Adjust the drive pinion preload by tightening the companion flange nut.





HINT: Use SST 09229 - 55010, 09330 - 00021 to hold the flange, then tighten the nut.

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





b. Using SST 09229 - 55010 and a torque wrench, measure the preload. Preload (at starting):
New bearing: 1.3 - 1.7 Nm (11.5 - 14.9 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.)

HINT: For vehicle which have run 8,000 km (5,000 miles) or less, if the preload value measured disassembly is greater than the specification for a reused bearing, return the preload to the same as before disassembly.





10. Install the drive pinion side bearing in the differential carrier first, as shown in the illustration, then install the differential case in carrier.





11. Install side bearing outer races.
a. Using SST 09608 - 32010, 09950 - 70010 (09951 - 07150), install the outer race on the drive pinion side.

HINT: Tap down on the outer race until half the groove of the snap ring of the differential carrier can be seen.

Fig. 15 Installing Outer Race:

b. Install SST on the differential carrier. SST 09571 - 50010
c. Tighten the SST bolt until the disc of the SST touches the side bearing outer race lightly.





d. Using SST 09608 - 32010, 09950 - 70010 (09951 - 07150 and a hammer, install the outer race on the ring gear side.

HINT: Drive in the outer race until it makes contact with the rollers of the side bearing.





12. Temporarily select snap ring on ring gear side.
a. Using snap ring pliers, fit the thinnest snap ring on the ring gear side. Snap ring thickness: 3.66 mm (0.144 inch)

Fig. 5 Dial Indicator Placement For Spreading Housing:

b. Install a dial indicator on the differential carrier.
c. Tighten the SST bolt inward to spread the differential carrier 0.10 mm (0.0039 inch)

HINT: Tighten the SST bolt to apply a preload to the side bearings.





d. Rotate the ring gear back and forth to settle the side bearings down.
e. Using a dial indicator, measure the backlash of the ring gear at 3 positions at least. Backlash: 0.08 - 0.13 mm (0.0031 - 0.0051 inch)

NOTICE: The difference between the maximum and minimum measured values must be 0.05 mm (0.0020 inch) or less.

HINT: The measured values should be used for reference when selecting snap rings, so note the values. If the backlash is not within the specification, replace the snap ring on the ring gear side with one of a different thickness using the following procedure.

f. Loosen the SST bolt until the SST disc separates from the side bearing outer race on the drive pinion side.

Fig. 6 Snap Ring Removal:

g. Using SST 09608 - 32010, 09950 - 70010 (09951 - 07150) and a hammer, make a gap between the outer race and snap ring on the ring gear side.





h. Using snap ring pliers, remove the snap ring on the ring gear side.
i. Using snap ring pliers. install a snap ring with a different thickness.

HINT:
- Snap rings in 39 different thickness in 0.02 mm (0.0008 inch) units are available. Refer to Component Service for ring gear selection.
- The backlash will change about 0.02 mm (0.0008 inch) with 0.02 mm (0.0008 inch) alteration of the snap ring.





j. Using a plastic hammer, tap on the differential carrier on the drive pinion side to eliminate any strain on the differential carrier.

Fig. 5 Dial Indicator Placement For Spreading Housing:

k. Install a dial indicator on the differential carrier.
l. Tighten the SST bolt inward and spread the differential carrier 0.10 mm (0.0039inch).





m. Using a dial indicator, measure the ring gear backlash.
Backlash 0.08 - 0.13 mm (0.0031 - 0.0051 inch)
If the backlash is still not within the specification, replace the snap ring on the ring gear side with one of another thickness. Application and ID

Fig. 5 Dial Indicator Placement For Spreading Housing:

13. Adjust backlash and total preload.
a. Install a dial indicator on the differential carrier.
b. Tighten the SST bolt inward and spread the differential carrier 0.10 mm (0.0039 inch)





c. Using snap ring pliers, fit the thickest snap ring that will fit in the drive pinion side.
d. Remove the dial indicator, then loose the SST bolt until the SST disc separate from the outer race.





e. Tap on the drive pinion side of the differential carrier with a plastic hammer to settle the side bearing down.





f. Confirm the backlash around the entire circumference of the ring gear. If there is no backlash at even 1 point, replace the snap ring on the drive pinion side with a thicker one.





g. Using SST 09229 - 55010 and a torque wrench, measure the total preload.
Total preload (at staring): Drive pinion preload plus
New bearing: 1.7 - 2.3 Nm (14.7 - 19.9 inch lbs.)
Reused bearing: 0.9 - 1.4 Nm (7.9 - 12.1 inch lbs.)
If the measured preload is less than the specification, replace the snap ring on the drive pinion side with a thicker one.
If the measured preload is greater than the specification, replace the snap ring on the drive pinion side with a thinner one.

HINT: Changing the snap ring thickness by 0.02 mm (0.008 inch) will change the total preload by approx. 0.1 Nm (0.9 inch lbs.).





h. Using a dial indicator, measure the ring gear backlash.
Backlash: 0.08 - 0.13 mm (0.0031 - 0.0051 inch)
If the backlash is not within the specification, replace the snap ring and make the necessary adjustment.

HINT:
- If the backlash is greater than the specification, replace the snap ring on the ring gear side with a thicker one, then replace the snap ring on the drive pinion side with a snap ring which is thinner to the same extant that the ring gear side snap ring is thicker.
- If the backlash is less than the specification, replace the snap ring on the ring gear side with a thinner one, then replace the snap ring on the drive pinion side with a snap ring which is thicker to the same extant that the ring gear side snap ring is thinner.
- The backlash will change about 0.02 mm (0.0008 inch) with 0.02 mm (0.0008 inch) alteration of the snap ring.
- When adjusting the backlash, keep the backlash, average as close to 0.10 mm (0.0039 inch) as possible.

i. Recheck the total preload.

Fig. 17 Proper Contact Pattern:

14. Inspect tooth contact pattern.
a. Coat 3 or 4 teeth at the 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 tooth contact pattern is not correct, replace the adjusting washer installed on the front of the drive pinion rear bearing to adjust it.

NOTICE:
- Make sure to always use a new part when replacing adjusting washer.
- Refer to the table below for selection of the adjusting washer.
- Adjust washers in 42 (different thicknesses in 0.01 mm (0.004 inch) units are available.

15. Install spacer on drive pinion.
a. Remove the 2 snap rings.
b. Remove the 2 side bearing outer races.
c. Remove the differential case.
d. Remove the drive pinion.
e. Install a new spacer on the drive pinion.
f. Install the drive pinion and front bearing.
g. Install the oil slinger.
16. Install front oil seal.
a. Apply MP grease to a new front oil seal lip.





b. Using SST 09316 - 60011 (09316 - 00011, 09316 - 00061), install the front oil seal until its end is flush with the surface of the differential carrier.

Fig. 14 Pinion Flange Installation:

17. Install companion flange using SST 09223 - 56010, 09325 - 40010 and a press, install the companion flange.

NOTICE: Be careful not to damage the oil seal.





18. Adjust drive pinion preload.
a. Coat the threads and flange of a new nut with hypoid gear oil for Limited Slip Differential (LSD).
b. Using SST 09229 - 55010, 09330 - 00021, tighten the nut to 147 Nm (108 ft. lbs.)





c. Using SST 09229 - 55010 and a torque wrench, measure the preload. Preload (at starting):
New bearing: 1.3 - 1.7 Nm (11.5 - 14.9 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (4.4 - 6.9 inch lbs.)
If the preload is greater than the specification, replace the spacer.
If the preload is less than the specification, retighten the nut 13 Nm (9 ft. lbs.) at a time until the specified preload is reached.
Maximum torque: 490 Nm (362 ft. lbs.)





If the maximum torque is exceeded with retightening the nut, replace the spacer and repeat the preload procedure.
Do not back off the nut to reduce the preload.
19. Check runout of drive pinion shaft.
20. Install differential case in carrier.
21. Install side bearing outer races.





22. Install snap rings.
a. Using snap ring pliers, install the snap ring on the ring gear side.

HINT: Use the snap ring which was fitted when the tooth contact pattern was adjusted.

Fig. 5 Dial Indicator Placement For Spreading Housing:

b. Install a dial indicator on the differential carrier.
c. Tighten the SST bolt inward and spread the differential carrier.

NOTICE: Pay attention to the dial indicator so as not to spread the differential carrier too wide. Maximum: 0.20 mm (0.0079 inch)





d. Using snap ring pliers, install the snap ring on the drive pinion side.

HINT: Use the snap ring which was fitted when the tooth contact pattern was adjusted.





e. Remove the dial indicator, then tap on the drive pinion side of the differential carrier with a plastic hammer to settle the side bearing down.
23. Recheck backlash, total preload and tooth contact pattern.





24. Stake drive pinion nut.





25. Install side oil seals using SST 09223 - 5601 0 and a hammer, install 2 new side oil seals until it is flush with the carrier end surface.





26. Install side gear shaft.
a. Using a plastic hammer, install the 2 side gear shafts.

NOTICE: Be careful not to damage the oil seal.

b. Install 2 new snap rings.





27. Install differential carrier cover.
a. Clean the contact surfaces of the carrier and cover of any residual FIPG material using cleaner.
b. Coat FIPG Part No. 08826 - 00090, THREE BOND 1281, or equivalent, to the carrier or cover.
c. Torque the set bolts to 47 Nm (34 ft. lbs.)

NOTICE: After installing the cover, wait at least 1 hour before filling it with oil or running the vehicle.