Reassembly

REAR DIFFERENTIAL CARRIER ASSEMBLY

COMPONENTS:

REASSEMBLY
1. INSTALL REAR DIFFERENTIAL PINION SHAFT PIN

a. Install the 2 thrust No. 1 washers to the 2 side gears.

NOTICE:
^ Make sure that there is no dirt or foreign matter on the thrust washer, side gear etc. before installing them.
^ If replacing either the side gear or pinion, replace them as a set.
^ Apply hypoid gear oil API GL-5 to all sliding and rotating parts.

b. Install the 2 side gears, 2 differential pinion gears, 2 differential pinion thrust washers and differential pinion shaft to the differential case.

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

c. Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

d. Measure the side gear backlash while holding 1 pinion gear toward the differential case.
Backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 inch)
If the backlash is not within the specified range, install the 2 side gear thrust No. 1 washers of different thicknesses.

HINT: Use the table to select the 2 side gear thrust No. 1 washer.

[2WD] Thrust Washer Thickness:

[4WD] Thrust Washer Thickness:

e. Using a pin punch (3 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft.

f. Using a chisel and a hammer, stake the outside of the differential case pin hole.
2. INSTALL DIFFERENTIAL RING GEAR

a. Clean the contact surfaces of differential case and ring gear.
b. Clean the differential ring gear set bolt hole.
c. Heat the ring gear to approximately 100°C (212°F) in boiling water.

CAUTION: Use thick gloves to protect hands as the ring gear is hot.

d. Carefully take the ring gear out of the boiling water.
e. Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

f. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

g. Align the matchmarks on the ring gear and differential case.
h. Temporarily install 5 new lock plates and 10 bolts.
i. After the ring gear cools down, tighten the 10 bolts uniformly.
Torque: 97 Nm (985 kgf-cm, 72 ft. lbs.)

j. Using a chisel and a hammer, stake the 5 lock plates.
1. Stake one claw so that it is flush against the flat surface of the bolt.
2. Stake the other claw against the surface of the bolt head to act as a stopper if the bolt starts to loosen.

3. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the case bearing inner race LH and RH to the differential case.
SST 09950-60010 (09951-00550, 09951-00560), 09950-70010 (09951-07100)

NOTICE:
^ Do not apply hypoid gear oil to a new bearing.
^ Do not deform the bearing cage.
^ Set the SST to the center of the differential case.
^ If the bearing is replaced, replace it and the outer race as a set.

4. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

a. Install the case bearing outer race LH and RH to the case bearing inner race LH and RH respectively

NOTICE: Be sure to install the bearing outer races in each correct position.

b. Install the differential case to the differential carrier.
c. Install the right and left (back side and teeth side) side gear shaft plate washers so that there is no looseness on the case bearing.
d. Install the right and left bearing caps with the 4 bolts.
Torque: 85 Nm (870 kgf-cm, 63 ft. lbs.)

e. Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
If the runout is greater than the maximum, replace the drive pinion, ring gear and differential case.
f. Remove the right and left bearing caps, 2 side gear shaft plate washers and differential case.

5. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, install the outer race of the rear drive pinion rear tapered roller bearing to the differential carrier.
SST 09950-60020 (09951-00790), 09950-70010 (09951-07200)

6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST and a press, install the outer race of the rear drive pinion front tapered roller bearing to the differential carrier.
SST 09950-60020 (09951-00720), 09950-70010 (09951-07100)

7. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Install the drive pinion plate washer to the drive pinion.
b. Using SST and a press, install the inner race of the rear drive pinion rear tapered roller bearing to the drive pinion.
SST 09506-30012

8. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

a. Install the drive pinion and the inner race of the rear drive pinion front tapered roller bearing to the differential carrier.

HINT: Assemble the drive pinion bearing spacer and oil seal after adjusting the gear contact pattern.

b. Install the drive pinion oil slinger to the drive pinion.

c. Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

NOTICE:
^ Install the companion flange so that there is slight looseness on the drive pinion because the bearing spacer is not installed.
^ Apply grease to the threads and tip of the SST center bolt before use.

d. Coat the threads of the drive pinion nut with hypoid gear oil LSD.

e. Using SST to hold the flange, tighten the drive pinion nut.
SST 09330-00021

HINT: Tighten the nut approximately 98 Nm (1,000 kgf-cm, 72 ft. lbs.), and tighten it further while checking the preload.

NOTICE:
^ Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.
^ As there is no bearing spacer, tighten the nut a little at a time and do not overtighten.

f. Turn the bearing clockwise and counterclockwise several times to stabilize it.

g. Using a torque wrench, measure the preload.
Drive pinion preload (at starting):
New bearing
2WD: 0.88 to 1.47 Nm (9.0 to 15.0 kgf-cm, 7.8 to 13.0 inch lbs.)
4WD: 1.30 to 1.90 Nm (13.3 to 19.4 kgf-cm, 11.5 to 16.8 inch lbs.)
Reused bearing
2WD: 0.39 to 0.69 Nm (4.0 to 7.0 kgf-cm, 3.5 to 6.1 inch lbs.)
4WD: 0.41 to 0.66 Nm (4.2 to 6.7 kgf-cm, 3.6 to 5.8 inch lbs.)

NOTICE: Record the preload for total preload measurement. If the preload is not within the specified range, adjust the differential drive pinion preload or repair as necessary.

9. INSTALL REAR DIFFERENTIAL CASE
a. Install the case bearing outer races LH and RH to the case bearing inner races LH and RH respectively.

NOTICE: Be sure to install the bearing outer races in each correct position.

b. Install the differential case to the differential carrier.

10. INSPECT DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH
a. Set the dial indicator perpendicular to the end of the ring gear face.
b. While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.
Backlash:
2WD: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)
4WD: 0.10 to 0.15 mm (0.0039 to 0.0059 inch)

11. ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH
a. Select a side gear shaft plate washer that will set ring gear backlash within the specified range, and install it to the ring gear back side.

HINT:
^ If the case bearing is new, select a thinner side gear shaft plate washer and install it.
^ If the case bearing is reused, install a side gear shaft plate washer with the same thickness as the removed one.

[2WD] Washer Thickness:

[4WD] Washer Thickness:

b. Make snug the differential case bearing and side gear shaft plate washer by tapping on the ring gear with a plastic hammer.

c. Set the dial indicator perpendicular to the end of the ring gear face.
d. While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.

HINT:
Backlash:
2WD: 0.13 mm (0.0051 inch)
4WD: 0.01 mm (0.0039 inch)

e. If the backlash is not within the specified range, select a side gear shaft plate washer that will set the ring gear backlash within the specified range and install it into the ring gear back side.

f. Select a thicker side gear shaft plate washer so that the clearance between the case bearing outer race end on the ring gear teeth side and the carrier becomes 0 or around 0.
g. Make the differential case bearing and side gear shaft plate washer snug by tapping on the ring gear with a plastic hammer.

h. Set the dial indicator perpendicular to the end of the ring gear face.
i. While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.
Backlash:
2WD: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)
4WD: 0.10 to 0.15 mm (0.0039 to 0.0059 inch)
If backlash is not within the specified range, adjust the thickness of the right and left side gear shaft plate washers by an equal amount so that the backlash comes within the specified range.

12. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

a. After adjusting the backlash of the differential ring gear, remove the teeth side gear shaft plate washer.
b. Using a micrometer, measure the thickness of the removed side gear shaft plate washer.
c. Select a new side gear shaft plate washer which is 0.06 to 0.09 mm (0.0024 to 0.0035 inch) thicker than the removed one.

HINT: Select a side gear shaft plate washer which can be pressed in 2/3 of the way with a finger.

d. Using SST and a plastic hammer, drive in the side gear shaft plate washer.
SST 09504-22011

e. Align matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps.

NOTICE: Make sure the right and left bearing caps are not interchanged.

f. Tighten both bearing caps with the 4 bolts.
Torque: 85 Nm (870 kgf-cm, 63 ft. lbs.)

g. Set the dial indicator to the end of the differential ring gear face.
h. While holding the rear drive pinion companion flange rear, rotate the differential ring gear and measure the backlash.
Backlash:
2WD: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)
4WD: 0.10 to 0.15 mm (0.0039 to 0.0059 inch)
If the measured value is out of the specified range, adjust it by increasing or decreasing the thickness of both right and left side gear shaft plate washers equally
13. INSPECT TOTAL PRELOAD

a. Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus 0.39 to 0.59 Nm (4.0 to 6.0 kgf-cm, 3.5 to 5.2 inch lbs.)
If the preload is not within the specified range, adjust it by the side gear shaft plate washer on the ring gear teeth side.

14. 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. Rotate the ring gear in both directions.

c. Inspect the tooth contact pattern.

d. If the teeth are not contacting properly, use the following table to select a proper washer for correction.

NOTICE:
^ If the contact pattern is face contact or flank contact, tooth contact may be adjustable while keeping the backlash within the specified range.
^ If the thickness of the drive pinion washer has been changed, adjust the backlash and measure the total preload.

Washer Thickness:

15. REMOVE REAR DRIVE PINION NUT
16. REMOVE REAR DRIVE PINION COMPANION FLANGE REAR
17. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

19. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install a new drive pinion bearing spacer to the drive pinion.

NOTICE: Be sure to face the larger inner diameter side rearward as shown in the illustration.

20. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Install the rear drive pinion front tapered roller bearing to the drive pinion.

21. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Install the drive pinion oil slinger to the drive pinion.

22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST and a hammer, install a new oil seal.
SST 09554-22010
Oil seal drive in depth: 1.55 to 2.45 mm (0.061 to 0.096 inch)
b. Apply MP grease to the oil seal lip.

23. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, install a new dust deflector.
SST 09636-20010

NOTICE:
^ Slowly press in the dust deflector.
^ If any burrs remain after pressing in the deflector, remove them.

24. INSTALL REAR DRIVE PINION COMPANION FLANGE REAR

a. Using SST, install the companion flange to the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

NOTICE: Apply grease to the threads and tip of the SST center bolt before use.

b. Coat the threads of a new drive pinion nut with hypoid gear oil LSD.

c. Using SST to hold the flange, tighten the drive pinion nut.
SST 09330-00021
Torque:
2WD: 338 Nm (3,450 kgf-cm, 249 ft. lbs.) or less
4WD: 223 Nm (2,280 kgf-cm, 164 ft. lbs.) or less

25. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the drive pinion.
Preload (at starting):
New bearing
2WD: 0.98 to 1.57 Nm (10.0 to 16.0 kgf-cm, 8.7 to 13.9 inch lbs.)
4WD: 1.4 to 2.0 Nm (14.3 to 20.4 kgf-cm, 12.4 to 17.7 inch lbs.)
Reused bearing
2WD: 0.49 to 0.78 Nm (5-0 to 8.0 kgf-cm, 4.3 to 6.9 inch lbs.)
4WD: 0.51 to 0.76 Nm (5.2 to 7.7 kgf-cm, 4.5 to 6.7 inch lbs.)
^ If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 10° to adjust it into the specified range.
^ If the preload is less than the specified minimum value even when the tightening torque of the drive pinion nut is greater than the specified maximum value, loosen the nut and check that the threads of the drive pinion nut and drive pinion are not stripped.
^ If the threads are not stripped, replace the bearing spacer. Apply hypoid gear oil LSD to the threads of the drive pinion and repeat the procedure.

26. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload.
Total preload (at starting): Drive pinion preload plus 0.39 to 0.59 Nm (4.0 to 6.0 kgf-cm, 3.5 to 5.2 inch lbs.)
If the total preload is not within the specified range, adjust the total preload or repair as necessary.

27. INSTALL REAR DRIVE PINION NUT
a. Using a chisel and hammer, stake the drive pinion nut.

28. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST and a hammer, install 2 new oil seals.
SST 09554-22010
Oil seal drive in depth:
2WD: -0.5 to 0.5 MM (-0.020 to 0.020 inch)
4WD: 0 to 1.0 mm (0 to 0.039 inch)
b. Apply MP grease to the oil seal lip.

29. REMOVE REAR DIFFERENTIAL CARRIER
a. Remove the differential carrier from the overhaul stand, etc.

30. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
a. Install the oil deflector and bolt to the carrier cover.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

31. INSTALL REAR DIFFERENTIAL CARRIER COVER
a. Clean any residual FIPG material on the contact surfaces using solvent.

b. Apply FIPG to the carrier cover.
FIPG: 08826-00090, THREE BOND 1281 or equivalent

HINT:
^ Apply FIPG in drops, approximately 2 to 3 mm (0.08 to 0.12 inch) in diameter on the entire surface.
^ Overlap FIPG at least 10 mm (0.39 inch) or more at the beginning and the end of application.
^ Install the carrier cover within 3 minutes after applying FIPG.
^ Do not add oil or drive the vehicle immediately after installing the cover. Leave it for at least an hour. Also, for at least 12 hours, avoid rapid acceleration/deceleration.

c. Install the carrier cover with the 8 bolts.
Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)

32. INSTALL REAR DIFFERENTIAL BREATHER PLUG
a. Install the breather plug to the carrier cover.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)

33. INSTALL REAR DIFFERENTIAL DRAIN PLUG
a. Using a hexagon wrench (10mm), install the differential drain plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)