Part 3

DIFFERENTIAL CARRIER ASSEMBLY REAR
OVERHAUL





50. INSTALL DIFFERENTIAL DRIVE PINION
a. Using SST and a press, install the front bearing outer race.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07100)
b. Install the drive pinion in the differential carrier.





c. Using SST and a press, install the front bearing on the drive pinion.
SST 09316-60011 (09316-00011), 09608-04031 (09951-07200)

HINT: Assemble the spacer and oil seal after adjusting the tooth contact pattern.

51. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD





a. Using SST, install the companion flange onto the differential carrier.
SST 09950-30012 (09951-03010, 09954-03010, 09956-03060, 09955-03040)

NOTICE:
^ Because the spacer is not installed, maintain a little looseness between the companion flange and the drive pinion when installing.
^ Apply hypoid gear oil to the SST center bolt tip and threads before use.





b. Adjust the drive pinion preload by tightening the companion flange nut.

HINT: Tighten the nut using approximately 98 Nm (1,000 kgf-cm) of force and then tighten it further while observing the preload.
Using SST to hold the flange, tighten the nut.

SST 09229-55010, 09330-00021





c. Using SST and a torque wrench, measure the preload.
Drive pinion preload (at starting):
New bearing: 1.5 to 2.0 Nm (15 to 21 kgf-cm, 13 to 18 inch lbs.)
Reused bearing: 0.5 to 0.8 Nm (5 to 8 kgf-cm, 4.3 to 6.9 inch lbs.)

HINT:
^ Do not apply hypoid gear oil if a new bearing is used.
^ Turn the bearing clockwise and counterclockwise several times to stabilize the bearing, and then measure the back lash.
^ If the preload is not within the specification, adjust the rear differential drive pinion preload or repair as necessary.





52. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
a. Install the drive side bearing in the differential carrier first, as shown in the illustration, then install the differential case.

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

53. INSTALL REAR DIFFERENTIAL CASE BEARING





a. Using SST and a hammer, install the drive pinion side outer race.
SST 09608-32010, 09950-70010 (09951-07200)

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





b. Place the SST to the differential carrier.
SST 09571-50010
c. Tighten the SST bolt until the SST disc lightly touches to the case bearing (outer race).





d. Using SST and a hammer, install the ring gear side outer race.
SST 09950-70010 (09951-07200), 09608-32010

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

54. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

HINT: This procedure is required only when final gear set (drive pinion & ring gear) is replaced.





a. Using snap ring pliers, install the thinnest side gear shaft shaft snap ring on the ring gear side.





b. Install a dial indicator to the differential carrier.
c. Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 inch).

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 inch).

HINT:
^ Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side gear shaft oil seal is tapped in.
^ Tighten the 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 at 3 positions.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)

NOTICE: The difference between the maximum and minimum values must be within 0.05 mm (0.020 inch).

HINT: Write the values for reference to select a side gear shaft shaft snap ring. If a value is not within the specified range, replace it with one of a different thickness in the following procedure.

f. Loosen the SST bolt and separate the SST disc from the case bearing (outer race) on the drive pinion.





g. Using SST and a hammer, create a clearance between the side shaft shaft snap ring on the ring gear side and outer race.
SST 09608-32010, 09950-70010 (09951-07200)





h. Using snap ring pliers, remove the side shaft shaft snap ring on the ring gear side.








i. Using snap ring pliers, install a side shaft shaft snap ring with different thickness.

HINT:
^ There are 39 different thicknesses of the side shaft shaft snap ring available in 0.02 mm (0.0008 inch) difference.
^ When the side shaft shaft snap ring thickness changes by 0.02 mm (0.0008 inch), the backlash changes by 0.02 mm (0.0008 inch).





j. Using a plastic hammer, lightly tap the drive pinion side of the differential carrier.





k. Install a dial indicator onto the differential carrier.
l. Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 inch).
SST 09571-50010

HINT: Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal tapped in.





m. Using a dial indicator, measure the ring gear backlash.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)
n. If the backlash is not within the specified range, replace the side shaft shaft snap ring on the ring gear side with one of a different thickness.





55. ADJUST DIFFERENTIAL RING GEAR BACKLASH
a. Install a dial indicator to the differential carrier.
b. Tighten the SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 inch).
SST 09571-50010

HINT: Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal tapped in.





c. Using snap ring pliers, install the thinnest side shaft shaft snap ring on the drive pinion side.
d. Remove the dial indicator and loosen the bolt until the SST disc is separated from the outer race.





e. Using a plastic hammer, lightly tap the drive pinion side of the differential carrier.





f. Check the backlash around the ring gear. If even one backlash is smaller than the specified value, adjust the differential ring gear backlash by replacing the side shaft shaft snap ring on the drive pinion side with a thicker one.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)

HINT: If a value is not within the specified range, replace it with one of a different thickness in the following procedure.

g. Loosen the SST bolt and separate the SST disc from the case bearing (outer race) on the drive pinion.





h. Using SST and a hammer, create a clearance between the side shaft shaft snap ring on the ring gear side and outer race.
SST 09608-32010, 09950-70010 (09951-07200)





i. Using snap ring pliers, remove the side shaft shaft snap ring on the ring gear side.








j. Using snap ring pliers, install a side shaft shaft snap ring with different thickness.

HINT:
^ There are 39 different thicknesses of the side shaft shaft snap ring available in 0.02 mm (0.0008 inch) difference.
^ When the side shaft shaft snap ring thickness changes by 0.02 mm (0.0008 inch), the backlash changes by 0.02 mm (0.0008 inch).





k. Using a plastic hammer, lightly tap the drive pinion side of the differential carrier.





l. Check the backlash around the ring gear. If even one backlash is smaller than the specified value, adjust the differential ring gear backlash by replacing the side shaft shaft snap ring on the drive pinion side with a thicker one.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)

HINT: If a value is not within the specified range, replace it with one of a different thickness in the same procedure.

56. 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
Total preload (at starting):
Drive pinion preload plus 0.46 to 1.37 Nm (4.69 to 13.97 kgf-cm, 4.07 to 12.13 inch lbs.)

NOTICE:
^ If the measured preload is less than the specification, replace the rear differential side shaft shaft snap ring of the ring gear's tooth surface side with a thicker one.
If the preload is greater than the specification, replace the rear differential side shaft shaft snap ring of the ring gear's tooth surface side with a thinner one.

HINT: When the rear differential side shaft shaft snap ring thickness changes by 0.02 mm (0.0008 inch), the total preload will change by approximately 0.1 Nm (1 kgf-cm, 0.9 inch lbs.).





b. Set a dial indicator to the end of the differential ring gear face.
c. While holding the rear drive pinion companion flange rear, rotate the differential ring gear and measure the backlash.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)

NOTICE:
^ If the measured value is out of the specified value, ad just it by increasing or decreasing the thickness of both right and left side shaft shaft snap ring equally.
^ When the side shaft shaft snap ring thickness changes by 0.02 mm (0.0008 inch), the backlash will change by approximately 0.02 mm (0.0008 inch).

d. Recheck the total preload.





57. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead primer.
b. Hold the companion flange firmly and rotate the ring gear in both directions.
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.

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

HINT: Refer to the table on the next page to select the adjusting washer.





HINT: There are 42 thicknesses of the rear differential drive pinion plate washers available in 0.01 mm (0.04 inch) difference.

58. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING





a. Install the SST to the rear differential carrier assembly.
SST 09571-50010





b. Install a dial indicator to the rear differential carrier assembly.
c. Tighten the SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.004 inch) clearance between the side bearing (outer race) and side shaft 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 inch).

HINT:
^ Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal tapped in.
^ Approximately 0.1 mm (0.004 inch) clearance between the side bearing (outer race) and the side shaft shaft snap ring is sufficient enough for the washer to move slightly.





d. Using snap ring pliers, remove the side shaft shaft snap ring on the drive pinion side.

HINT: For reassembly purposes, measure the thickness of the side shaft shaft snap ring. Write down the result.

e. Remove the dial indicator and loosen the SST bolt.

NOTICE: Do not remove the SST.

59. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING





a. Using SST and a hammer, create a clearance between the side bearing (outer race) on the ring gear and side shaft shaft snap ring.
SST 09608-32010, 09950-70010 (09951-07200)

HINT: The clearance cannot be seen, but tapping the SST with a hammer three or four times should be enough.





b. Using snap ring pliers, remove the side shaft shaft snap ring on the ring gear side.

HINT: For reassembly purposes, measure the thickness of the side shaft shaft snap ring. Write down the result.





60. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Tighten the SST bolt and push out the outer race on the ring gear side.
SST 09571-50010

NOTICE: Do not drop the side bearing (outer race).

b. Remove the SST





61. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Raise the ring gear side of the differential case slightly to remove the drive pinion side outer race.

HINT: For reassembly, check the installation position of the outer race and of the side shaft shaft snap ring before removing the outer race. Write down the result.





62. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

NOTICE: Do not damage the case bearing.





63. REMOVE REAR DRIVE PINION NUT
a. Using SST to hold the flange, remove the nut.
SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)





64. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
a. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03060, 09955-03040)
65. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Using a magnet hand, remove the differential drive pinion oil slinger.





66. REMOVE DIFFERENTIAL DRIVE PINION
a. Using a press, remove the drive pinion with the rear bearing from the differential carrier.

NOTICE: Be careful not to drop the drive pinion.





67. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Remove the front bearing from the differential carrier.





68. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install the spacer to the drive pinion.





69. INSTALL DIFFERENTIAL DRIVE PINION
a. Using SST and a press, install the drive pinion (rear bearing RR inner race) and rear drive pinion tapered roller bearing FR inner race to the differential carrier.
SST 09316-60011 (09316-00011), 09608-04031
70. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Install the rear differential drive pinion oil slinger to the differential drive pinion.





71. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
a. Perform this procedure only when replacing the dust cover.
b. Using SST and a press, insert a new dust deflector into the companion flange.
SST 09316-60011 (09316-00011)

NOTICE:
^ Slowly press a new dust deflector into the companion flange while observing the dust deflector. Do not press excessively.
^ If necessary, remove any burrs after inserting the new dust deflector.





72. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
a. Apply a small amount of MP grease to a new oil seal lip.
b. Using SST and a press, insert the new oil seal into the rear differential carrier.

NOTICE: Be sure that the oil seal is straight when inserting.

Oil seal drive in depth: 0 ± 0.5 mm (0 ± 0.020 inch)
SST 09316-60011 (09316-00011), 09710-04101





73. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
a. Using SST, install the companion flange to the differential carrier ASSEMBLY
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03060, 09955-03040)

NOTICE: Apply hypoid gear oil to the SST center bolt tip and threads before use.

b. Apply hypoid gear oil LSD to the threads of a new nut.





c. Using SST, hold the flange and tighten the nut while observing the preload with SST and torque wrench.
SST 09229-55010, 09330-00021
Torque: 98 Nm to 490 Nm (1000 kgf-cm to 5,000 kgf-cm, 72 ft. lbs. to 361 ft. lbs.)

NOTICE:
^ Do not tighten excessively, otherwise the threads will be stripped.
^ Apply hypoid gear oil LSD to the threads of the nut and drive pinion.

HINT: Tighten the nut using approximately 98 Nm (1,000 kgf-cm) of force and then tighten it further while observing the preload.





74. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
a. Insert the differential case from the ring gear tooth side to install.

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

75. INSTALL REAR DIFFERENTIAL CASE BEARING





a. Using SST and a hammer, install the drive pinion side outer race.
SST 09608-32010, 09950-70010 (09951-07200)

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





b. Place the SST to the differential carrier.
SST 09571-50010
c. Tighten the SST bolt until the SST disc lightly touches to the case bearing (outer race).





d. Using SST and a hammer, install the ring gear side outer race.
SST 09950-70010 (09951-07200), 09608-32010

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