Reassembly

FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)


REASSEMBLY
1. INSTALL DIFFERENTIAL CASE ASSEMBLY





(a) Install the 2 thrust washers No.1 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.
(1) Differential pinion gears [A]
(2) Differential pinion thrust washers [B]
(3) Differential pinion shaft [C]
(4) Differential side gears [D]
(5) Differential side gear thrust washers No.1 [E]

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

2. ADJUST DIFFERENTIAL PINION AND SIDE GEAR





(a) Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

(b) 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 in.)
If the backlash is not within the specified range, install the 2 side gear thrust washers No.1 of different thicknesses.

HINT: Refer to the following table to select the 2 side gear thrust washers No.1.

Washer thickness:

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





(d) Using a chisel and a hammer, stake the outside of the differential case pin hole.
3. INSTALL DIFFERENTIAL RING GEAR
(a) Clean the contact surfaces of the differential case and ring gear.





(b) 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.

(c) Carefully take the ring gear out of the boiling water.





(d) Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

(e) After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
(f) Align the matchmarks on the ring gear and differential case.
(g) Temporarily install 4 new lock plates and the 8 bolts.
(h) After the ring gear cools down, tighten the 8 bolts.
Torque: 97 N*m (985 kgf*cm, 71 ft.*lbf)





(i) Using a chisel and a hammer, stake the 4 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 start to loosen.





4. INSTALL FRONT DIFFERENTIAL CASE BEARING
(a) Using SST and a press, install the case bearing inner races LH to the differential case.
SST 09636-20010

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 bearing outer race as a set.





5. INSTALL FRONT DIFFERENTIAL CASE BEARING
(a) Using SST and a press, install the case bearing inner races RH to the differential case.
SST 09636-20010, 09950-60010 (09951-00410)

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 bearing outer race as a set.





6. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST, the bolt, nut (M12 X P1.25) and washer, install outer race of the rear tapered roller bearing.
SST 09950-60020 (09951-00710, 09951-00720)

NOTICE: Do not apply hypoid gear oil to a new bearing.

HINT:
^ Bolt: M12 X P1.25, bolt length: 186 mm (09101-12159)
^ Nut: M12 X P1.25 (09101-12159)





7. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Install the front adjust shim to the differential carrier.
(b) Using SST, the bolt, nut (M12 X P1.25) and washer, install outer race of the front tapered roller bearing.
SST 09950-60010 (09951-00640), 09950-60020 (09951-00810)

NOTICE: Do not apply hypoid gear oil to a new bearing.

HINT:
^ Bolt: M12 X P1.25, bolt length: 186 mm (09101-12159)
^ Nut: M12 X P1.25 (90179-12051)





8. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST and a press, install the inner race of the front drive pinion front tapered roller bearing to the drive pinion.
SST 09506-30012

NOTICE: Do not apply hypoid gear oil to a new bearing.





9. INSTALL FRONT DIFFERENTIAL CASE BEARING
(a) Install the case plate washer to the differential carrier.
(b) Using SST and a press, install the outer race of the front differential case bearing LH to the differential carrier.
SST 09950-60020 (09951-00730)

NOTICE: Do not apply hypoid gear oil to a new bearing.





10. INSTALL FRONT DIFFERENTIAL CASE BEARING
(a) Install the case plate washer to the differential side bearing retainer.
(b) Using SST and a press, install the outer race of the front differential case bearing RH to the differential side bearing retainer.
SST 09950-60020 (09951-00730)

NOTICE: Do not apply hypoid gear oil to a new bearing.

11. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Install the drive pinion, inner race of the front drive pinion rear tapered roller bearing and drive pinion oil slinger to the differential carrier.

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





(b) 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.





(c) Coat the threads of the drive pinion nut with hypoid gear oil LSD.
SST 09330-00021, 09950-30012 (09955-03030)
(d) Using SST to hold the flange, tighten the drive pinion nut.

HINT: Tighten the nut approximately 98 N*m (1,000 kgf*cm, 72 ft.*lbf), 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.

(e) Turn the bearing clockwise and counterclockwise several times to stabilize it.
(f) Using a torque wrench, measure the preload.
Drive pinion preload (at starting):
New bearing: 0.88 to 1.47 N*m (9.0 to 15.0 kgf*cm, 7.8 to 13.0 in.*lbf)
Reused bearing: 0.39 to 0.68 N*m (4.0 to 7.0 kgf*cm, 3.5 to 6.0 in.*lbf)

NOTICE:
^ Record the preload for total preload measurement.
^ Do not apply hypoid gear oil to a new bearing.

If the preload is not within the specified range, adjust the differential drive pinion preload or repair as necessary.

12. INSTALL FRONT DIFFERENTIAL CASE
(a) Install the differential case to the differential carrier.
13. INSPECT AND ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION





(a) Install the differential side bearing retainer with the 8 bolts.
Torque: 58 N*m (590 kgf*cm, 43 ft.*lbf)





(b) Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle.





(c) Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand.
SST 09564-32011
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0512 in.)

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

Washer thickness:

(d) If backlash is not within the specified range, change the thickness of the right and left case washers by equal amounts to adjust it.





14. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus 0.29 to 0.49 N*m (3.0 to 5.0 kgf*cm, 2.6 to 4.3 in.*lbf)

NOTICE:
^ If the total preload is not within the specified range, replace the case washer on the ring gear teeth side with another one to adjust it.
^ Do not apply hypoid gear oil to a new bearing.

15. TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION





(a) Remove the 8 bolts and side bearing retainer.
(b) Remove the differential case from the differential carrier.





(c) Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead primer.
(d) Install the differential case to the differential carrier.





(e) Install the differential side bearing retainer with the 8 bolts.
Torque: 58 N*m (590 kgf*cm, 43 ft.*lbf)
(f) Rotate the ring gear in both directions.
(g) Remove the 8 bolts and side bearing retainer.
(h) Remove the differential case from the differential carrier.
(i) Inspect the tooth contact pattern.








(j) If the teeth are not contacting properly, use the following table to select a proper plate washer for correction.

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

Washer thickness:

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





20. INSTALL FRONT 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.

21. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING





(a) Using the companion flange, install the inner race of the front drive pinion rear tapered roller bearing to the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03020, 09955-03030)

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





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

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

22. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER





23. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL
(a) Join the 2 SST and secure them with vinyl tape.
SST 09309-36010, 09502-12010
(b) Using SST and a hammer, install a new oil seal.
SST 09309-36010, 09502-12010
Oil seal drive in depth: 0.7 to 1.3 mm (0.028 to 0.051 in.)
(c) Apply MP grease to the oil seal lip.





24. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR
(a) Install the differential side bearing retainer deflector with the bolt.
Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)





25. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR
(a) Using SST and a press, install a new dust deflector.
SST 09316-60011 (09316-00011)

NOTICE:
^ Slowly press in the dust deflector but not excessively.
^ If any burrs remain after pressing in the deflector, remove them.





26. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT
(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, 09950-30012 (09955-03030)
Torque: 108 to 235 N*m (1100 to 2400 kgf*cm, 80 to 173 ft.*lbf)
27. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the preload of the drive pinion.
Preload (at starting):
New bearing: 0.98 to 1.57 N*m (10.0 to 160 kgf*cm, 8.7 to 13.9 in.*lbf)
Reused bearing: 0.49 to 0.78 N*m (5.0 to 8.0 kgf*cm, 4.3 to 6.9 in.*lbf)
^ 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.
28. INSTALL DIFFERENTIAL CASE ASSEMBLY
(a) Install the differential case to the differential carrier.





29. APPLICATION SEAL PACKING
(a) Check that there are no foreign objects or damage to the installation surface of the side bearing retainer.
(b) Apply FIPG to the side bearing retainer.
FIPG: 08826-00090, THREE BOND 1281 or equivalent

HINT:
^ Apply FIPG in drops, approximately 2 to 3 mm (0.08 to 0.12 in.) in diameter on the entire surface.
^ Overlap FIPG at least 10 mm (0.39 in.) 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.





30. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER
(a) Install the differential side bearing retainer with the 8 bolts.
Torque: 58 N*m (590 kgf*cm, 43 ft.*lbf)





31. INSTALL FRONT DIFFERENTIAL BREATHER PLUG
(a) Install the differential breather plug to the differential carrier.
Torque: 21 N*m (210 kgf*cm, 15 ft.*lbf)





32. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus 0.29 to 0.49 N*m (3.0 to 5.0 kgf*cm, 2.6 to 4.3 in.*lbf)
If the total preload is not within the specified range, adjust the total preload or repair as necessary.
33. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION





(a) Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle.





(b) Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand.
SST 09564-32011
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0512 in.)
If the backlash is not within the specified range, adjust the ring gear backlash or repair as necessary.





34. INSPECT RUNOUT OF FRONT DRIVE PINION COMPANION FLANGE FRONT
(a) Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
Maximum runout: 0.05 mm (0.0020 in.)
If the runout is greater than the maximum, replace the companion flange.





35. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
(a) Using a chisel and hammer, stake the drive pinion nut.





36. INSTALL FRONT DIFFERENTIAL CASE OIL SEAL
(a) Using SST and a hammer, install 2 new oil seals.
SST 09613-22011, 09950-60010 (09951-00560)
Oil seal drive in depth:
1.0 to 2.0 mm (0.039 to 0.079 in.) (LH Side)
7.5 to 8.5 mm (0.295 to 0.335 in.) (RH Side)
(b) Apply MP grease to the oil seal lips.
37. INSTALL FRONT DIFFERENTIAL DRAIN PLUG
(a) Install the differential drain plug and a new gasket.
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)





38. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY
(a) Remove the differential carrier from the overhaul stand, etc.