Part 1

DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY

1. INSTALL DIFFERENTIAL RING GEAR

(a) Clean the differential ring gear set bolt hole.

(b) Heat the ring gear approximately 100°C (212°F) in boiling water.

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

(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.

HINT
Align the rear differential case bolt holes and differential ring gear screw holes.

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

NOTICE:
Do not overtighten the vise.

(f) Apply thread lock adhesive to the threads and flanges of 10 new differential case bolts.

NOTICE:
As the differential case bolts are plastic region tightening bolts, do not reuse them.

(g) Temporarily tighten the 10 differential case bolts uniformly in several passes, and then tighten them to the torque specification.

Torque : 64 Nm (652 kgf-cm, 47 ft-lbf)

NOTICE:
* Tighten the bolts after the ring gear has sufficiently cooled down.
* Install the differential case bolts by tightening diametrically opposite pairs uniformly in several passes.

(h) Tighten the bolts further by 60° to 90°.

NOTICE:
Tighten the bolts in diametrically opposite pairs.

2. INSTALL REAR DIFFERENTIAL CASE BEARING

(a) Using SST and a press, press in the case bearing inner race LH and RH to the differential case.

SST : 09950-60010

09951-00560

09951-00570

SST : 09950-70010

09951-07100

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

3. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using SST and a press, press in the rear drive pinion rear tapered roller bearing inner race to the drive pinion.

SST : 09316-60011

09316-00031

SST : 09612-10093

09613-22011

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

HINT
Disassemble SST (09613-22011), and only use the pipe part.

(b) Using SST and a press, press in the rear drive pinion rear tapered roller bearing outer race and drive pinion washer.

SST : 09950-70010

09951-07200

SST : 09255-10012

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

HINT
Select a drive pinion washer of the same thickness as the one removed.

4. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Using SST and a press, press in the rear drive pinion front tapered roller bearing outer race.

SST : 09950-60020

09951-00710

SST : 09950-70010

09951-07100

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

5. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

HINT
Perform this procedure only when replacing the dust deflector.

(a) Using SST and a press, insert a new dust deflector into the companion flange.

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.

6. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Install the rear drive pinion front tapered roller bearing inner race from the differential carrier.

7. INSTALL DIFFERENTIAL DRIVE PINION

(a) Using SST and a press, press in the differential drive pinion.

SST : 09316-60011

09316-00011

09316-00041

SST : 09608-04031

NOTICE:
* Install the spacer and oil seal after performing the ring gear tooth contact pattern inspection adjustment.
* Make sure the press, SST and drive pinion are in a straight line when pressing.
* Do not forcefully press in the bearing.
* Do not apply hypoid gear oil to a new bearing.

8. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Install the drive pinion oil slinger.

9. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

(a) Using SST, install the companion flange.

SST : 09950-30012

09951-03010

09954-03010

09955-03040

09956-03060

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

(b) Using SST and a torque wrench, install a new drive pinion nut.

SST : 09229-55010

SST : 09330-00021

SST : 09950-30012

09955-03040

Maximum torque:

T=490 N*m {5000 kgf*cm 361 ft.*lbf}

NOTICE:
* Tighten the nut with a force of 100 N*m (1020 kgf*cm) while checking the starting torque of the drive pinion.
* As the bearing spacer is not installed, tighten the drive pinion nut little by little. Do not overtighten the nut.
* Do not overtighten the nut, as the threads will become damaged.
* Coat the threads the drive pinion nut and drive pinion with hypoid gear oil LSD.
* Perform the removal while supporting the overhaul attachment.

(c) For a more accurate measurement, rotate the bearing forward and backward before the inspection.

(d) Using SST and a torque wrench, measure the preload.

SST : 09229-55010

Standard drive pinion preload (at starting):

New bearing
1.12 to 1.70 N*m (11.4 to 17.3 kgf*cm, 9.9 to 15.0 in.*lbf)

Reused bearing
0.4 to 0.7 N*m (4.1 to 7.2 kgf*cm, 3.5 to 6.2 in.*lbf)

NOTICE:
Record the preload for total preload measurement.

10. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY

(a) Insert the differential case from the ring gear tooth side to install it.

NOTICE:
Do not damage the case bearing and ring gear.

11. INSTALL REAR DIFFERENTIAL CASE BEARING

(a) Using SST and a hammer, tap in the ring gear tooth side case bearing outer race.

SST : 09608-32010

SST : 09950-70010

09951-07200

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

HINT
Tap in the case bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.

(b) Install the 2 bolts and SST to the differential carrier.

SST : 09571-50010

(c) Tighten SST bolt until SST disc lightly touches the case bearing outer race.

(d) Using SST and a hammer, tap in the ring gear back surface side case bearing outer race.

SST : 09608-32010

SST : 09950-70010

09951-07200

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

HINT
Tap in the case bearing outer race until it touches the case bearing inner race roller bearing.

12. ADJUST DIFFERENTIAL RING GEAR BACKLASH

(a) Using snap ring pliers, install a side gear shaft snap ring on the back surface of the ring gear.

If the final gear set (drive pinion and ring gear) or differential case bearing are replaced, select and install the thinnest differential side gear shaft snap ring first.

If the differential case bearing, ring gear, or drive pinion are reused, select and install a differential side gear shaft snap ring with the same thickness as the one before the disassembly first.

(b) Install a dial indicator to the differential carrier.

(c) Tighten SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).

SST : 09571-50010

NOTICE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

HINT
* Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.
* Tighten SST bolt to apply the preload to the case bearing.

(d) Turn the ring gear clockwise and counterclockwise several times.

(e) Using a dial indicator, measure the backlash of the ring gear.

Standard backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE:
Measure at 3 or more areas around the circumference of the ring gear.

HINT
* Record the measured value, as it is used to select the differential side gear shaft snap ring.
* Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential side gear shaft snap ring.

If the measured value is not within the specified range, replace the ring gear side differential side gear shaft snap ring with one of a different thickness in the next step.

(f) Loosen the thinnest side gear shaft snap ring on the ring gear tooth side.

(g) Using SST and a hammer, tap the ring gear back surface side to create clearance between the differential case bearing outer race and the differential side gear shaft snap ring of the ring gear back surface side.

SST : 09608-32010

SST : 09950-70010

09951-07200

HINT
The clearance is not visible, but tapping SST with a hammer 3 or 4 times should be enough.

(h) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.

(i) Using snap ring pliers, install a side gear shaft snap ring with a different thickness than the one removed.

HINT
When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash also changes by 0.02 mm (0.0008 in.).

Standard snap ring thickness:

(j) Using a plastic-faced hammer, lightly tap the ring gear tooth side of the differential carrier.

(k) Install a dial indicator to the differential carrier.

(l) Tighten SST bolt to alter the differential carrier's shape approximately 0.1 mm (0.004 in.).

SST : 09571-50010

NOTICE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in).

HINT
* Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.
* Tighten SST bolt to apply the preload to the case bearing.

(m) Place a dial indicator so that it is perpendicular to the top of the ring gear on the tooth side.

(n) Fix the companion flange in place by hand, and measure the ring gear backlash.

Standard backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE:
Measure the ring gear at 3 or more different places.

If the measured value is not within the specified range, replace the ring gear back surface side differential side gear shaft snap ring with one of a different thickness.

HINT
* Record the measured value, as it is used to select the differential side gear shaft snap ring.
* Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential side gear shaft snap ring.
* When adjusting the backlash, adjust to within 0.1 mm of the average of the measurements.

13. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

(a) Install a dial indicator to the differential carrier.

(b) Tighten SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).

SST : 09571-50010

NOTICE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

HINT
Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.

(c) Using snap ring pliers, install a side gear shaft snap ring on the ring gear tooth side.

If the backlash is not within the specified range, adjust it to the specified range by increasing or decreasing the thickness of the right and left side differential side gear shaft snap rings equally.

(d) Remove the dial indicator and loosen the thinnest side gear shaft snap ring on the ring gear tooth side.

HINT
Do not remove SST.

(e) Using a plastic-faced hammer, lightly tap the ring tooth side of the differential carrier to stabilize the differential case bearing.

(f) Place a dial indicator on the tip of the ring gear tooth at a right angle.

(g) Fix the companion flange in place by hand, and measure the ring gear backlash.

Standard backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE:
Measure at 3 or more areas around the circumference of the ring gear.

If the backlash is small even in one place, replace the ring gear tooth side differential side gear shaft snap ring with a thicker one.

HINT
* Record the measured value, as it is used to select the differential side gear shaft snap ring.
* Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential side gear shaft snap ring.
* When adjusting the backlash, adjust to within 0.1 mm of the average of the measurements.

(h) Remove the 2 bolts and SST from the differential carrier.

14. ADJUST TOTAL PRELOAD

(a) Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

SST : 09229-55010

Standard total preload (at starting):

New bearing
1.58 to 3.07 N*m (16.1 to 31.3 kgf*cm, 14.0 to 27.2 in.*lbf)

Reused bearing
0.86 to 2.07 N*m (8.8 to 21.1 kgf*cm, 7.6 to 18.3 in.*lbf)

If the measured preload is below the standard value, replace the differential side gear shaft snap ring with a thicker one.

If the measured preload is above the standard value, replace the differential side gear shaft snap ring with a thinner one.

NOTICE:
* If the thickness of the differential side gear shaft snap ring changes 0.02 mm, the total preload will change approximately 0.1 N*m (1.0 kgf*cm).
* For reassembly purposes, record the measured value.

(b) Place a dial indicator on the tip of the ring gear tooth at a right angle.

(c) While holding the companion flange, rotate the ring gear and measure the backlash.

Standard backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE:
Measure at 3 or more areas around the circumference of the ring gear.

If the backlash is not within the specified range, adjust it to the specified range by increasing or decreasing the thickness of the right and left side differential side gear shaft snap rings equally.

HINT
* When adjusting the backlash, adjust to within 0.1 mm of the average of the measurements.
* When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash will also change by approximately 0.02 mm (0.0008).
* Record the measured value, as it is used to select the differential side gear shaft snap ring.
* Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential side gear shaft snap ring.

(d) Recheck the total preload.

15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

(a) Uniformly apply a light coat of Prussian blue on both sides of 4 teeth on the differential ring gear.

(b) Rotate the companion flange several times in the forward and backward rotation directions.

NOTICE:
Check the tooth contact pattern at 4 or more positions around the circumference of the ring gear.

HINT
The patterns indicated by the Prussian blue are the tooth contact locations.

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

NOTICE:
Make sure to always replace the drive pinion washer with a new one.

Standard washer thickness:

16. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING

(a) Install the 2 bolts and SST to the differential carrier.

SST : 09571-50010

(b) Tighten SST bolt until SST disc lightly touches the case bearing outer race.

(c) Install a dial indicator to the rear differential carrier.

(d) Tighten SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.004 in.) clearance between the case bearing outer race and side gear shaft snap ring.

NOTICE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

HINT
* Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.
* The approximate 0.1 mm clearance between the differential case bearing outer race and the differential side gear shaft snap ring only needs to be enough so that the differential side gear shaft snap ring can move slightly.

(e) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.

HINT
Place distinguishing marks on the left and right side differential side gear shaft snap rings to distinguish them (back surface side, tooth side). Then store them separately.

(f) Remove the dial indicator and loosen the thinnest side gear shaft snap ring on the ring gear tooth side.

HINT
Do not remove SST.

17. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING

(a) Using SST and a hammer, create a clearance between the case bearing outer race on the ring gear and side gear shaft snap ring.

SST : 09608-32010

SST : 09950-70010

09951-07200

HINT
The clearance is not visible, but tapping SST with a hammer 3 or 4 times should be enough.

(b) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surfaces side.

HINT
Place distinguishing marks on the left and right side differential side gear shaft snap rings to distinguish them (back surface side, tooth side). Then store them separately.