Steps 1 - 19

FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

COMPONENTS:

REASSEMBLY (STEPS 1 - 19)

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

HINT: Use the 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 Nm (985 kgf-cm, 71 ft. lbs.)

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 P 1.25, bolt length: 186 mm (09101-12159)
^ Nut: M12 X P 1.25 (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 P 1.25, 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 Nm (1,000 kgf-cm, 72 ft. lbs.), 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 Nm (9.0 to 15.0 kgf-cm, 7.8 to 13.0 inch lbs.)
Reused bearing: 0.39 to 0.68 Nm (4.0 to 7.0 kgf-cm, 3.5 to 6.0 inch lbs.)

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 Nm (590 kgf-cm, 43 ft. lbs.)

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 inch)

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 Nm (3.0 to 5.0 kgf-cm, 2.6 to 4.3 inch lbs.)

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 Nm (590 kgf-cm, 43 ft. lbs.)
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