Rear Differential Carrier Reassembly

Hold the differential case in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0 mm (0 in.).
If not, replace the rear differential case sub-assembly with a new one.

Clean the contact surfaces of the differential case and ring gear.

Clean the differential ring gear set bolt hole.

Heat the ring gear to approx. 100°C (212°F) in boiling water.

CAUTION:

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

Carefully take the ring gear out of the boiling water.

Hold the differential case in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

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

Align the matchmarks on the ring gear and differential case.

Temporarily install 5 new lock plates and 10 bolts.

After the ring gear cools down, tighten the 10 bolts uniformly.

Torque:

97 N*m{985 kgf*cm, 72 ft.*lbf}

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.
   

Using SST and a press, install the case bearing inner races LH and RH to the differential case.

SST

09950-60010(09951-00430,09951-00580,09951-00590,09952-06010)
09950-70010(09951-07100)
09710-04081

NOTICE:

1. Do not apply hypoid gear oil to a new bearing.
   
2. Do not deform the bearing cage.
   
3. Place the SST carefully on the inner races of the bearings or on the center of the differential case (as applicable).
   
4. If the bearing is replaced, replace it and the outer race as a set.
   

Using a dial indicator, measure the runout of the ring gear.

Maximum runout:

0.07 mm (0.0028 in.)

Install the drive pinion plate washer to the drive pinion.

HINT:

1. Temporarily install the inner race of the rear drive pinion rear tapered roller bearing to prevent the drive pinion washer from being dropped.
   
2. The drive pinion washer can be installed in either direction.
   

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

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(09951-00890)
09950-70010(09951-07200)

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)

Using SST and a press, install a new dust deflector.

SST

09636-20010

NOTICE:

1. Slowly press in the dust deflector.
   
2. If any burrs remain after pressing in the deflector, remove them.
   

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

NOTICE:

1. Do not drop the drive pinion.
   
2. Install the drive pinion bearing spacer and oil seal after adjusting the gear contact pattern.
   

Install the drive pinion oil slinger to the drive pinion.

Using SST, install the companion flange.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03030,09956-03030)

NOTICE:

1. Hold the drive pinion until the SST is installed.
   
2. Install the companion flange so that there is slight looseness on the drive pinion because the bearing spacer is not installed.
   
3. Apply grease to the threads and tip of the SST center bolt before use.
   

Using SST to hold the flange, tighten the drive pinion nut.

SST

09330-00021

Torque:

338 N*m (3,450 kgf*cm, 249 ft.*lbf) or less

NOTICE:

1. Tighten the nut to approximately 100 N*m (1,020 kgf*cm, 74 ft.*lbf), and tighten it further while checking the preload.
   
2. Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.
   
3. As there is no bearing spacer, tighten the nut a little at a time and do not overtighten it.
   

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

Using a torque wrench, measure the drive pinion preload.

Drive pinion preload (at starting):

Specifications	Preload
New bearing	1.39 to 2.49 N*m (14.2 to 25.4 kgf*cm, 12.3 to 22.0 in.*lbf)
Reused bearing	1.01 to 1.81 N*m (10.3 to 18.5 kgf*cm, 8.9 to 16.0 in.*lbf)

NOTICE:

1. Record the preload for total preload measurement.
   
2. Do not apply hypoid gear oil to a new bearing.
   

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.

Install the differential case to the differential carrier.

Install the right and left (on the back and tooth sides) side gear shaft washers so that the case bearing is not loose.

HINT:

1. If the final gear set (drive pinion and ring gear) and case bearing are new, select a thinner side gear shaft plate washer and install it.
   
2. If the final gear set (drive pinion and ring gear) and case bearing are reused, install a side gear shaft plate washer with the same thickness as the removed one.
   

Set the dial indicator perpendicular to the end of the ring gear face.

While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

Backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

HINT:

1. Record the measured backlash to use as a reference for selecting a side gear shaft plate washer.
   
2. Inspect tooth contact to use the result as a reference for selecting a side gear shaft plate washer.
   

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.

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

Set the dial indicator perpendicular to the end of the ring gear face.

While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.

Backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

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.

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 zero or close to zero.

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

Set the dial indicator perpendicular to the end of the ring gear face.

While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

Backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

After adjusting the backlash of the differential ring gear, remove the teeth side side gear shaft plate washer.

Using a micrometer, measure the thickness of the removed side gear shaft plate washer.

Select a new side gear shaft plate washer which is 0.06 to 0.09 mm (0.0024 to 0.0035 in.) 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.

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

SST

09504-22011

Align the 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.

Tighten both bearing caps with the 4 bolts.

Torque:

85 N*m{870 kgf*cm, 63 ft.*lbf}

Set the dial indicator to the end of the differential ring gear face.

While holding the rear drive pinion companion flange rear, rotate the differential ring gear and measure the backlash.

Backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

HINT:

1. Record the measured backlash to use as a reference for selecting a side gear shaft plate washer.
   
2. Inspect tooth contact to use the result as a reference for selecting a side gear shaft plate washer.
   

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

Preload (at starting):

Specifications	New drive pinion tapered roller bearing	Reused drive pinion tapered roller bearing
New differential case bearing	2.47 to 4.16 N*m (25.2 to 42.4 kgf*cm, 21.9 to 36.8 in.*lbf)	2.09 to 3.48 N*m (21.3 to 35.5 kgf*cm, 18.5 to 30.8 in.*lbf)
Reused differential case bearing	1.88 to 3.27 N*m (20.2 to 33.3 kgf*cm, 16.6 to 28.9 in.*lbf)	1.50 to 2.59 N*m (15.3 to 26.4 kgf*cm, 13.3 to 22.9 in.*lbf)

HINT:

1. If the measured preload is less than the specified value, replace the side gear shaft plate washer of the ring gear tooth surface side with a thicker one.
   
2. If the preload is greater than the specified value, replace the side gear shaft plate washer of the ring gear tooth surface side with a thinner one.
   

Set the dial indicator perpendicular to the end of the ring gear face.

While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.

Backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

HINT:

1. If the backlash is not within the specified range, change the thickness of the right and left side gear shaft plate washers by equal amounts to adjust it.
   
2. Record the measured backlash to use as a reference for selecting a side gear shaft plate washer.
   
3. Inspect tooth contact to use the result as a reference for selecting a side gear shaft plate washer.
   

Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.

Rotate the ring gear in both directions.

Inspect the tooth contact pattern.

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

NOTICE:

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

Using SST to hold the flange, remove the drive pinion nut.

Using SST, remove the companion flange.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03030,09956-03030)

NOTICE:

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

Remove the drive pinion oil slinger.

Using SST, remove the inner race of the rear drive pinion front tapered roller bearing from the drive pinion.

SST

09556-22010

NOTICE:

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

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.

Install the rear drive pinion front tapered roller bearing to the drive pinion.

Install the drive pinion oil slinger to the drive pinion.

Using SST and companion flange, install the rear drive pinion front tapered roller bearing.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03030,09956-03030)

NOTICE:

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

Using SST, remove the companion flange.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03030,09956-03030)

NOTICE:

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

Using SST and a hammer, install a new oil seal.

SST

09554-22010

Oil seal installation depth:

1.55 to 2.45 mm (0.061 to 0.096 in.)

Apply MP grease to the oil seal lip.

Using SST, install the companion flange.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03030,09956-03030)

NOTICE:

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

Using SST to hold the flange, tighten the drive pinion nut.

SST

09330-00021

Torque:

338 N*m (3,450 kgf*cm, 249 ft.*lbf) or less

NOTICE:

1. Tighten the nut to approximately 100 N*m (1,020 kgf*cm, 74 ft.*lbf), and tighten it further while checking the preload.
   
2. Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.
   

Using a torque wrench, measure the preload of the drive pinion.

Drive Pinion Preload (at starting):

Specifications	Preload
New bearing	1.49 to 2.59 N*m (15.2 to 26.4 kgf*cm, 13.2 to 22.9 in.*lbf)
Reused bearing	1.11 to 1.91 N*m (11.3 to 19.5 kgf*cm, 9.8 to 16.9 in.*lbf)

1. 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.
   

   Torque:

   338 N*m (3,450 kgf*cm, 249 ft.*lbf) or less
   

2. 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.
   
3. 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.
   

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

Preload (at starting):

Specifications	New drive pinion tapered roller bearing	Reused drive pinion tapered roller bearing
New differential case bearing	2.57 to 4.26 N*m (26.2 to 43.4 kgf*cm, 22.7 to 37.7 in.*lbf)	2.19 to 3.58 N*m (22.3 to 36.5 kgf*cm, 19.4 to 31.7 in.*lbf)
Reused differential case bearing	1.98 to 3.37 N*m (20.2 to 34.4 kgf*cm, 17.5 to 29.8 in.*lbf)	1.60 to 2.69 N*m (16.3 to 27.4 kgf*cm, 14.2 to 23.8 in.*lbf)

Set the dial indicator perpendicular to the end of the ring gear face.

While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

Backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

HINT:

1. Record the measured backlash to use as a reference for selecting a side gear shaft plate washer.
   
2. Inspect tooth contact to use the result as a reference for selecting a side gear shaft plate washer.
   

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.

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

Set the dial indicator perpendicular to the end of the ring gear face.

While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.

Backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

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.

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 zero or close to zero.

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

Set the dial indicator perpendicular to the end of the ring gear face.

While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

Backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

Using a dial indicator, measure the runout of the companion flange vertically and horizontally.

Maximum runout:

0.09 mm (0.0035 in.)

Using a SST and a hammer, stake the drive pinion nut.

SST

09930-00010

Using SST and a hammer, install 2 new oil seals.

SST

09213-70011
09950-60010(09951-00410,09951-00620,09952-06010)
09950-70010(09951-07100)

Oil seal installation depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

Apply MP grease to the oil seal lip.

Using a hexagon wrench (10 mm), install the differential drain plug with a new gasket.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

Remove the differential carrier from the overhaul stand, etc.

Install the oil deflector and bolt to the carrier cover.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Clean any residual FIPG material on the contact surfaces using gasoline or alcohol.

Apply FIPG to the carrier cover.

FIPG:

08826-00090, THREE BOND 1281 or equivalent

HINT:

1. Apply FIPG in a continuous bead, approximately 2 to 3 mm (0.08 to 0.12 in.) in diameter on the entire sealing surface.
   
2. Overlap FIPG at least 10 mm (0.39 in.) or more at the beginning and the end of application.
   
3. Install the carrier cover within 3 minutes after applying FIPG.
   
4. Do not fill the differential with oil or drive the vehicle immediately after installing the differential carrier cover. Allow at least one hour for the sealant to dry before filling the differential. Avoid sudden acceleration and deceleration for at least 12 hours after installation of parts using FIPG sealant.
   

Install the carrier cover with the 8 bolts.

Torque:

47 N*m{480 kgf*cm, 35 ft.*lbf}

Install the breather plug to the carrier cover.

Torque:

21 N*m{210 kgf*cm, 15 ft.*lbf}