Assembly
1. Adjust differential pinion gear backlash, as follows:
a. Install the two proper thrust washers on the side gears.
NOTE: Using the specifications listed below, 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 two side gears, pinion gears, pinion gear thrust washers and pinion shaft in the differential case.
NOTE: Align the holes of the differential case and pinion shaft.
c. Push the two 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 two side gear thrust washers with different thicknesses.
e. Remove the two side gear shafts.
2. Install ring gear on the differential case, as follows:
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, as follows:
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.
NOTE: Align the matchmarks on the ring gear and the differential case.
e. Tighten two 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, as follows:
a. After the ring gear has cooled sufficiently, install new ten ring gear set bolts to which the thread lock has been applied.
Thread lock: Part No. 08833 - 00100, THREE BOND 1360 K or equivalent.
NOTICE: New ring gear set bolts should be used in every case.
b. Torque the ten set bolts uniformly and a little at a time.
Torque: 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 Special Service Tool (SST) 09710 - 30050, 09950 - 60010 (09951 - 00450), 09950 - 70010 (09951 - 07150) or equivalents, and a press, install the two side bearings.
6. Install drive pinion bearing outer races and adjusting washer, as follows:
NOTE: The adjusting washer is used for adjusting the tooth contact pattern. 42 types of washer 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. When removing an adjusting washer, be sure to replace it with a new one.
a. Using SST 09950 - 60020 (09951 - 00710), 09950 - 70010 (09951 - 07150) or equivalents, and a press, install the front bearing outer race.
b. Using SST 09250 - 10011 (09252 - 10010, 09255 - 10011) or equivalents, and a press, install a new adjusting washer the rear bearing outer race.
Fig. 35 Installing Rear Bearing To Drive Pinion:
7. Install rear bearing to drive pinion. Using SST 09502 - 24010 or equivalent, and a press, install the rear bearing.
8. Temporarily install drive pinion, front bearing, oil slinger and companion flange, as follows:
a. Install the drive pinion in the differential carrier.
b. Using SST 09316 - 60011 (09316 - 00011), 09608 - 30012 (09608 - 04030) or equivalents, and a press, install the front bearing on the drive pinion.
NOTE: Assemble the spacer and oil seal after adjusting the tooth contact pattern.
c. Install the oil slinger.
Fig. 14 Pinion Flange Installation:
d. Using SST 09223 - 46011, 09325 - 40010 or equivalents, and a press, install the companion flange.
9. Temporarily adjust drive pinion preload, as follows:
a. Adjust the drive pinion preload by tightening the companion flange nut.
NOTE: Using SST 09229 - 55010, 09330 - 00021 or equivalents, to hold the flange, 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 or equivalent, and a torque wrench, measure the preload.
Preload (at starting):
New bearing: 1.5 - 1.8 Nm (13.0 - 15.6 inch lbs.).
Reused bearing: 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.).
NOTE: 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.
Fig. 36 Installing Side Bearing Outer Race & Adjusting Washer:
10. Install side bearing outer races and adjusting plate washers. Using SST 09950 - 60020 (09951 - 00810), 09950 - 70010 (09951 - 07150) or equivalents, and a press, install the two washers and two outer races.
11. Install differential case in carrier. Install the drive side bearing in the differential carrier first, as shown in the illustration, then install the differential case.
12. Install differential carrier retainers, as follows:
a. Using SST 09950 - 60020 (09951 - 00890), 09950 - 70010 (09951 - 07150) or equivalents, and a hammer, install the two carrier retainers.
b. Tighten the bolts.
Torque: 22 Nm (16 ft. lbs.).
13. Check ring gear backlash. Using a dial indicator, measure the backlash of the ring gear at three 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 less than 0.05 mm (0.0020 inch).
NOTE: The measured values should be used for reference when selecting washers, so make a memo of the values.
If the backlash is not within the specification replace the washer on the ring gear side with one of a different thickness using the following procedure.
Ring Gear Backlash:
Adjusting washer thickness.
14. Measure total preload. Using SST 09229 - 55010 or equivalent, and a torque wrench, measure the total preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus: 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.).
If the measured preload is less than the specification, replace the washer of the ring gear's tooth surface side with a thicker one. If the preload is greater than the specification, replace the washer of the ring gear's tooth surface side with a thinner one.
NOTE: Changing the snap ring thickness by 0.02 mm (0.0008 inch) will change the total preload by approximately 0.1 Nm (0.9 inch lbs.).
15. Inspect tooth contact pattern, as follows:
a. Coat three or four teeth at the three different positions on the ring gear with red lead.
b. Hold the companion flange firmly and rotate the ring gear in both directions.
Fig. 17 Proper Contact Pattern:
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.
NOTE:
- Refer to the table for selection of the adjusting washer.
Adjusting Washers:
- Adjusting washers in 42 different thickness in 0.01 mm (0.004 inch) units are available.
16. Remove differential retainers.
17. Remove differential case.
18. Remove drive pinion.
19. Install spacer on drive pinion. Install a new spacer on the drive pinion.
20. Install drive pinion and front bearing.
21. Install oil slinger.
22. Install oil seal, as follows:
a. Apply Multipurpose (MP) grease to a new oil seal lip.
b. Using SST 09316 - 60011 (09316 - 00011, 09316 - 00041) 09502 - 12010 or equivalents, install the oil seal until its end is flush with the surface of the differential carrier.
Fig. 14 Pinion Flange Installation:
23. Install companion flange. Using SST 09223 - 63010, 09325 - 40010 or equivalent, and a press, install the companion flange.
NOTICE: Be careful not to damage the oil seal.
24. Adjust drive pinion preload, as follows:
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 or equivalent, tighten the nut.
c. Using SST 09229 - 55010 or equivalent, and a torque wrench, measure the preload. If the preload is greater than the specification, replace the spacer.
Preload (at starting):
New bearing: 1.5-1.8 Nm (13.0 - 15.6 inch lbs.).
Reused bearing: 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.).
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 while retightening the nut, replace the spacer and repeat the preload procedure. Do not back off the nut to reduce the preload.
25. Check runout of drive pinion shaft.
26. Install differential case in carrier.
27. Install O-rings from differential carriers retainers, as follows:
a. Coat two new O-rings with hypoid gear oil.
b. Install the two O-rings to the two differential carrier retainers.
28. Install oil seals from differential carrier retainers, as follows:
Fig. 26 Removing Side Bearing Outer Race & Plate Washer:
a. Using SST 09608 - 32010, 09950 - 70010 (09950 - 07150) or equivalents, and a press, install two new oil seals to the two carrier retainers.
b. Coat the MP grease to the oil seal lip.
29. Install differential carrier retainers.
30. Recheck backlash, total preload and tooth contact pattern.
31. Stake drive pinion nut.
32. Install snap rings to side gear shafts, as follows:
a. Install two new snap rings to the shafts.
b. Coat the MP grease to the snap rings.
33. Install side gear shafts. Using a brass bar and hammer install the two side gear shafts.
NOTE: Whether or not the side gear shaft is making contact with the pinion shaft can be known by the sound or feeling when driving it in.
NOTICE: Be careful not to damage the oil seal.
34. Remove differential carrier from overhaul stand, etc.
35. Install differential carrier cover, as follows:
a. Clean the contact surfaces of the carrier and cover of any residual Formed In Place Gasket (FIPG) material using cleaner.
b. Coat FIPG to the carrier or cover.
FIPG: Part No. 08826 - 00090, THREE BOND 1281 or equivalent
NOTICE: After installing the cover. wait at least one hour before filling it with oil or running the vehicle.
c. Install the carrier cover to the carrier with the eight bolts.
Torque: 47 Nm (34 ft. lbs.).
d. Install the breather plug.
Torque: 21 Nm (15 ft. lbs.).