Steps 20 - 38

FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

COMPONENTS:

REASSEMBLY (STEPS 20 - 38)

20. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
a. 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.

21. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

a. Using the companion flange, install the inner race of the front drive pinion rear tapered roller bearing to the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03020, 09955-03030)

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

b. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09956-03020, 09955-03030)

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

22. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

23. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL
a. Join the 2 SST and secure them with vinyl tape.
SST 09309-36010, 09502-12010
b. Using SST and a hammer, install a new oil seal.
SST 09309-36010, 09502-12010
Oil seal drive in depth: 0.7 to 1.3 mm (0.028 to 0.051 inch)
c. Apply MP grease to the oil seal lip.

24. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR
a. Install the differential side bearing retainer deflector with the bolt.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)

25. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, install a new dust deflector.
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.

26. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT

a. Using SST, install the companion flange to the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

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

b. Coat the threads of a new drive pinion nut with hypoid gear oil LSD.

c. Using SST to hold the flange, tighten the drive pinion nut.
SST 09330-00021, 09950-30012 (09955-03030)
Torque: 108 to 235 Nm (1100 to 2400 kgf-cm, 80 to 173 ft. lbs.)

27. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the drive pinion. Preload (at starting):
New bearing: 0.98 to 1.57 Nm (10.0 to 160 kgf-cm, 8.7 to 13.9 inch lbs.)
Reused bearing: 0.49 to 0.78 Nm (5.0 to 8.0 kgf-cm, 4.3 to 6.9 inch lbs.)
^ 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.
^ 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.
^ 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.

28. INSTALL DIFFERENTIAL CASE ASSEMBLY
a. Install the differential case to the differential carrier.

29. APPLICATION SEAL PACKING
a. Check that there are no foreign objects or damage to the installation surface of the side bearing retainer.
b. Apply FIPG to the side bearing retainer.
FIPG: 08826-00090, THREE BOND 1281 or equivalent

HINT:
^ Apply FIPG in drops, approximately 2 to 3 mm (0.08 to 0.12 inch) in diameter on the entire surface.
^ Overlap FIPG at least 10 mm (0.39 inch) or more at the beginning and the end of application.
^ Install the carrier cover within 3 minutes after applying FIPG.
^ Do not add oil or drive the vehicle immediately after installing the cover. Leave it for at least an hour. Also, for at least 12 hours, avoid rapid acceleration/deceleration.

30. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER
a. Install the differential side bearing retainer with the 8 bolts.
Torque: 58 Nm (590 kgf-cm, 43 ft. lbs.)

31. INSTALL FRONT DIFFERENTIAL BREATHER PLUG
a. Install the differential breather plug to the differential carrier.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)

32. 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.)
If the total preload is not within the specified range, adjust the total preload or repair as necessary.

33. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION

a. 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.

b. 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)
If the backlash is not within the specified range, adjust the ring gear backlash or repair as necessary.

34. INSPECT RUNOUT OF FRONT DRIVE PINION COMPANION FLANGE FRONT
a. Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
Maximum runout: 0.05 mm (0.0020 inch)
If the runout is greater than the maximum, replace the companion flange.

35. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
a. Using a chisel and hammer, stake the drive pinion nut.

36. INSTALL FRONT DIFFERENTIAL CASE OIL SEAL
a. Using SST and a hammer, install 2 new oil seals.
SST 09613-22011, 09950-60010 (09951-00560)
Oil seal drive in depth:
1.0 to 2.0 mm (0.039 to 0.079 inch) (LH Side)
7.5 to 8.5 mm (0.295 to 0.335 inch) (RH Side)
b. Apply MP grease to the oil seal lips.

37. INSTALL FRONT DIFFERENTIAL DRAIN PLUG
a. Install the differential drain plug and a new gasket.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)

38. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY
a. Remove the differential carrier from the overhaul stand, etc.