Assembly

1. Adjust the differential pinion gear backlash by doing the following.





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.
(1)Thrust Washer Thickness : 1.6 mm (0.063 inch).
(2)Thrust Washer Thickness : 1.8 mm (0.071 inch).
(3)Thrust Washer Thickness : 1.7 mm (0.067 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. The backlash should be 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 the ring gear on differential case by doing the following.





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 the ring gear on differential case after doing the following.
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.

NOTE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently.

4. Install the ring gear set bolts by doing the following.





a. After the ring gear has cooled sufficiently, install new 10 ring gear set bolts to which Part No. 08833 - 00100, THREE BOND 1360 K or equivalent. thread lock has been applied.

NOTE: New ring gear set bolts should be used in every case.

b. Tighten the 10 set bolts to 64 Nm (47 ft. lbs.), uniformly and a little at a time.





c. Tighten the bolts an additional 60 - 90°.

NOTE: Tighten the bolts in diagonally opposite pairs.





5. Using the 09710 - 30050, 09950 - 60010 (09951 - 00450), 09950-70010 (09951 -07150) SST and a press, install the two side bearings.

6. Install the drive pinion bearing outer races and the adjusting washer.

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 the 09950 - 60020 (09951 - 00710), 09950-70010 (09951 -07150) SST and a press, install the front bearing outer race.
b. Using the 09250 - 10011 (09252 - 10010, 09255 - 10011) SST and a press, install a new adjusting washer the rear bearing outer race.

Fig. 35 Installing Rear Bearing To Drive Pinion:

7. Using the 09502 - 24010 SST and a press, install the rear bearing to the drive the pinion.
8. Temporarily install the drive pinion, front bearing, oil slinger and the companion flange by doing the following.
a. Install the drive pinion in the differential carrier.





b. Using the 09316 - 60011 (09316 - 00011), 09608-30012 (09608-04030) SST 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 the 09223 - 46011, 09325 - 40010 SST and a press, install the companion flange.

9. Temporarily adjust the drive pinion preload by doing these procedures.
a. Adjust the drive pinion preload by tightening the companion flange nut.





NOTE:
- Using the 09229 - 55010, 09330 - 00021 SST to hold the flange, tighten the nut.

- As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.





b. Using the 09229 - 55010 SST and a torque wrench, measure the preload. The preload (at starting) measurements are as follows. For a new bearing it should be 1.5 - 1.8 Nm (13.0 - 15.6 inch lbs.), and for a reused bearing it should be 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.).

NOTE: For vehicles 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. Using the 09950 - 60020 (09951 - 00810), 09950-70010 (09951 -07150) SST and a press, install the two adjusting plate washers and the side bearing outer races.





11. Install the drive side bearing in the differential carrier first, as shown in the illustration, then install the differential case.
12. Install the differential carrier retainers by doing the following procedures.





a. Using the 09950 - 60020 (09951 - 00890), 09950-70010 (09951 -07150) SST and a hammer, install the two carrier retainers.
b. Tighten the 16 bolts to 22 Nm (16 ft. lbs.).





13. Using a dial indicator, measure the backlash of the ring gear at three positions at least. The backlash should measure 0.08 - 0.13 mm (0.0031 - 0.0051 inch).

NOTE:
- The difference between the maximum and minimum measured values must be less than 0.05 mm (0.0020 inch).

- 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.


NOTE: The adjusting washer thickness are as follows.
No.2: 2.02 mm (0.0795 inch).
No.4: 2.04 mm (0.0803 inch).
No.6: 2.06 mm (0.0811 inch).
No.8: 2.08 mm (0.0819 inch).
No.10: 2.10 mm (0.0827 inch).
No.12: 2.12 mm (0.0835 inch).
No.14: 2.14 mm (0.0843 inch).
No.16: 2.16 mm (0.0850 inch).
No.18: 2.18 mm (0.0858 inch).
No.20: 2.20 mm (0.0866 inch).
No.22: 2.22 mm (0.0874 inch).
No.24: 2.24 mm (0.0882 inch).
No.26: 2.26 mm (0.0890 inch).
No.28: 2.28 mm (0.0898 inch).
No.30: 2.30 mm (0.0906 inch).
No.32: 2.32 mm (0.0913 inch).
No.34: 2.34 mm (0.0921 inch).
No.36: 2.36 mm (0.0929 inch).
No.38: 2.38 mm (0.0937 inch).
No.40: 2.40 mm (0.0945 inch).
No.42: 2.42 mm (0.0953 inch).
No.44: 2.44 mm (0.0961 inch).
No.46: 2.46 mm (0.0969 inch).
No.48: 2.48 mm (0.0976 inch).
No.50: 2.50 mm (0.0984 inch).
No.52: 2.52 mm (0.0992 inch).
No.54: 2.54 mm (0.1000 inch).
No.56: 2.56 mm (0.1008 inch).
No.58: 2.58 mm (0.1016 inch).
No.60: 2.60 mm (0.1024 inch).
No.62: 2.62 mm (0.1031 inch).
No.64: 2.64 mm (0.1039 inch).
No.66: 2.66 mm (0.1047 inch).
No.68: 2.68 mm (0.1055 inch).
No.70: 2.70 mm (0.1063 inch).
No.72: 2.72 mm (0.1071 inch).
No.74: 2.74 mm (0.1079 inch).
No.76: 2.76 mm (0.1087 inch).
No.78: 2.78 mm (0.1094 inch).
No.80: 2.80 mm (0.1102 inch).
No.82: 2.82 mm (0.1110 inch).
No.84: 2.84 mm (0.1118 inch).
No.86: 2.86 mm (0.1126 inch).





14. Using the 09229 - 55010 and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. The total preload (at starting) drive pinion preload plus should be 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.).

NOTE:
- 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.

- Changing the snap ring thickness by 0.02 mm (0.0008 inch) will change the total preload by approx. 0.1 Nm (0.9 inch lbs.).

15. Inspect the tooth contact pattern by doing these steps.





a. Coat 3 or 4 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.





NOTE:
- Make sure to always use a new part when replacing adjusting washer.
No.87: 1.87 mm (0.0736 inch).
No.88: 1.88 mm (0.0740 inch).
No.89: 1.89 mm (0.0744 inch).
No.90: 1.90 mm (0.0748 inch).
No.91: 1.91 mm (0.0752 inch).
No.92: 1.92 mm (0.0756 inch).
No.93: 1.93 mm (0.0760 inch).
No.94: 1.94 mm (0.0764 inch).
No.96: 1.95 mm (0.0768 inch).
No.97: 1.96 mm (0.0772 inch).
No.98: 1.97 mm (0.0776 inch).
No.99: 1.98 mm (0.0780 inch).
No.00: 1.99 mm (0.0783 inch).
No.01: 2.01 mm (0.0791 inch).
No.02: 2.02 mm (0.0795 inch).
No.03: 2.03 mm (0.0799 inch).
No.04: 2.04 mm (0.0803 inch).
No.05: 2.05 mm (0.0807 inch).
No.06: 2.06 mm (0.0811 inch).
No.07: 2.07 mm (0.0815 inch).
No.08: 2.08 mm (0.0819 inch).
No.09: 2.09 mm (0.0823 inch).
No.10: 2.10 mm (0.0827 inch).
No.11: 2.11 mm (0.0831 inch).
No.12: 2.12 mm (0.0835 inch).
No.13: 2.13 mm (0.0839 inch).
No.14: 2.14 mm (0.0843 inch).
No.15: 2.15 mm (0.0846 inch).
No.16: 2.16 mm (0.0850 inch).
No.17: 2.17 mm (0.0854 inch).
No.18: 2.18 mm (0.0858 inch).
No.19: 2.19 mm (0.0862 inch).
No.20: 2.20 mm (0.0866 inch).
No.21: 2.21 mm (0.0870 inch).
No.22: 2.22 mm (0.0874 inch).
No.23: 2.23 mm (0.0878 inch).
No.24: 2.24 mm (0.0882 inch).
No.25: 2.25 mm (0.0886 inch).
No.26: 2.26 mm (0.0890 inch).
No.27: 2.27 mm (0.0894 inch).
No.28: 2.28 mm (0.0898 inch).



NOTE: Adjust washers in 42 (different thicknesses in 0.01 mm (0.004 inch) units are available.

16. Remove the differential retainers.
17. Remove the differential case.
18. Remove the drive pinion.
19. Install a new spacer on the drive pinion.
20. Install the drive pinion and the front bearing.
21. Install the oil slinger.
22. Install the oil seal by following these procedures.
a. Apply MP grease to a new oil seal lip.





b. Using the 09316 - 60011 (09316 - 00011, 09316 - 00041) 09502- 12010 SST, install the oil seal until its end is flush with the surface of the differential carrier.

Fig. 14 Pinion Flange Installation:

23. Using the 09223 - 63010, 09325 - 40010 SST and a press, install the companion flange.

NOTE: Be careful not to damage the oil seal.

24. Adjust the drive pinion preload, doing the following.
a. Coat the threads and flange of a new nut with hypoid gear oil for LSD.





b. Using the 09229 - 55010, 09330 - 00021 SST, tighten the nut.





c. Using the 09229 - 55010 SST and a torque wrench, measure the preload. The preload (at starting) measurements are as follows. For the new bearing it should be 1.5 - 1.8 Nm (13.0 - 15.6 inch lbs.) and for the reused bearing it should be 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.)

NOTE:
- If the preload is greater than the specification, replace the spacer.





- If the preload is less than the specification, retighten the nut 13 Nm (9 ft. lbs.) at a time until they specified preload is reached. The maximum torque is 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 the runout of the drive pinion shaft.
26. Install the differential case into the carrier.





27. Install the O-rings from the differential carrier retainers by doing these steps.
a. Coat 2 new O-rings with hypoid gear oil.
b. Install the 2 O-rings to the carrier retainers.

28. Install the oil seals from the differential carrier retainers doing the following.

Fig. 26 Removing Side Bearing Outer Race & Plate Washer:

a. Using the 09608 - 32010, 09950 - 70010 (09950 - 07150) SST and a press, install two new oil seals to the carrier retainers.
b. Coat the MP grease to the oil seal lip.

29. Install the differential carrier retainers.
30. Recheck the backlash, total preload and the tooth contact pattern.





31. Stake the drive pinion nut.
32. Install the snap rings to the side gear shafts, doing the following
a. Install two new snap rings to the side gear shafts.
b. Coat the MP grease to the snap rings.





33. Using a brass bar and hammer install the 2 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.

- Be careful not to damage the oil seal.

34. Remove the differential carrier from the overhaul stand, etc.
35. Install the differential carrier cover by doing the following.





a. Clean the contact surfaces of the carrier and cover of any residual FIPG material using cleaner.
b. Coat Part No. 08826 - 00090, THREE BOND 1281 or equivalent FIPG to the carrier or cover.

NOTE: 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, tightening the bolts to 47 Nm (34 ft. lbs.).
d. Install the breather plug, tightening it to 21 Nm (15 ft. lbs.).