Part 2 of 2
OVERHAUL55. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear to about 100°C (212°F) 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 ten differential case.
e. Align the matchmarks on the ring gear and differential case.
f. After the ring gear cools down enough, torque the set bolts to which thread lock has been applied.
Thread lock:
Part No.08833-00100, THREE BOND 1360k or equivalent.
Torque: 97 Nm (985 kgf-cm, 71 ft. lbs.)
56. INSTALL FRONT DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the 2 case bearings (inner) into the differential case.
SST 09950-60010 (09951-00520, 09951-00610), 09950-70010 (09951-07150)
57. INSTALL FRONT DIFFERENTIAL CASE BEARING
HINT: When replacing the 2 differential case bearings, fit the 2 thin nest washers to each bearing and when reusing the bearings, fit the washers with the same thickness as removed.
a. Using SST and a press, install the case bearing (outer) outer race to the differential case bearing retainer. (RH side)
SST 09950-60020 (09951-00810), 09950-70010 (09951-07150)
b. Install a new case washer to the side bearing retainer. (LH side)
SST 09950-60020 (09951-00810), 09950-70010 (09951-07150)
58. INSTALL BEARING OUTER RACE
a. Using SST, install the tapered roller bearings (outer) FR.
SST 09950-00020 (09951-00890), (09951-00680)
b. Using a brass bar and a hammer, install the oil storage ring.
c. Using SST, install the tapered roller bearings (outer) RR.
SST 09950-00020 (09951-00890), (09951-00680)
59. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Install the washer on the drive pinion.
HINT: First fit a washer with the same thickness with the removed washer, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.
b. Using SST and a press, install the front bearing onto the drive pinion.
SST 09506-30012
60. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Install the drive pinion and oil slinger.
HINT: Assemble the spacer and oil seal after adjusting the ring gear tooth contact pattern.
b. Using SST, install the rear bearing, oil slinger and companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020).
c. Coat the threads of the nut with hypoid gear oil.
d. Adjust the drive pinion preload by tightening the companion flange nut.
Using SST to hold the flange, tighten the nut.
SST 09330-00021 (09330-00030)
Torque: 370 Nm (3770 kgf-cm, 273 ft. lbs.) or less
NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.
e. Using a torque wrench, measure the preload.
Preload (at starting)
New bearing: 0.98 - 1.57 Nm (1 - 16 kgf-cm, 8.7 - 13.9 inch lbs.)
Reused bearing: 0.49 - 0.78 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
61. INSTALL DIFFERENTIAL CASE ASSY
62. ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION
a. Install the side bearing retainer with the 10 bolts.
Torque: 50 Nm (510 kgf-cm 37 ft. lbs.)
b. Using SST and a dial indicator, measure the ring gear backlash.
SST 09564-32011
Backlash: 0.11 - 0.18 mm (0.0043 - 0.0071 inch)
c. If it is not within the specification, adjust it by either in creasing or decreasing the washers on both sides by an equal amount.
HINT: There should be no clearance between the plate washer and case.
Make sure that there is ring gear backlash.
Washer thickness
63. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus 0.20 - 0.63 Nm (2 - 6 kgf-cm, 1.8 - 5.6 inch lbs.)
64. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Remove the differential case bearing retainer and differential case.
b. Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead.
c. Install the differential case and differential case bearing retainer.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
d. Hold the companion flange firmly and rotate the ring gear in both directions.
e. Remove the differential case bearing retainer and differential case.
f. Inspect the tooth contact pattern.
If the teeth are not contacting properly, use the following chart to select a proper washer for correction.
Washer thickness
65. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
SST 09330-00021
66. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSY FRONT
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09503030, 09956-03020)
67. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
68. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
SST 09556-22010
69. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install a new bearing spacer to the drive pinion.
70. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
71. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
72. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL
a. Using SST and a hammer, install the oil seal.
SST 09554-22010
Oil seal drive in depth: 4.35 ± 0.45 mm (0.1713 ± 0.0177 inch)
73. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR
a. Using a steel plate and a press, install a new dust deflector.
NOTICE: Do not damage the dust deflector.
74. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSY FRONT
a. Place the companion drive pinion companion flange on the drive pinion.
b. Coat the threads of a new nut with hypoid gear oil.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
c. Using SST to hold the drive pinion companion flange, torque the nut.
SST 09330-00021 (09330-00030)
Torque: 370 Nm (3,770 kgf-cm, 273 ft. lbs.) or less
75. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
a. Remove any old FIPG material and be not to drop oil on the contact surfaces of the differential carrier and side bearing retainer.
b. Clear contacting surfaces of any residual FIPG material using gasoline or alcohol.
c. Apply FIPG to the side bearing retainer, as shown.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
HINT: Install the bearing retainer within 10 minutes after applying FIPG.
d. install the side bearing retainer with the 10 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
76. INSPECT DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting)
New bearing: 0.98 - 1.57 Nm (10 - 16 kgf-cm, 8.7 - 13.9 inch lbs.)
Reused bearing: 0.49 - 0.78 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
If the preload is greater than the specification, replace the bearing spacer.
If the preload is less than the specification, retighten the nut 13 Nm (130 kgf-cm, 9 ft. lbs.) a little at a time until the specified preload is reached.
Torque: 370 Nm (3,770 kgf-cm, 273 ft. lbs.) or less
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the nut to reduce the preload.
77. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus 0.20 - 0.63 Nm (2 - 6 kgf-cm, 1.8 - 5.6 inch lbs.)
If necessary, disassemble and inspect the differential.
78. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION
a. Using SST and a dial indicator, measure the ring gear backlash.
SST 09564-32011
Backlash: 0.11 - 0.18 mm (0.0043 - 0.0071 inch)
79. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSY FRONT
a. Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
Maximum runout:
Vertical runout: 0.10 mm (0.0039 inch)
Lateral runout: 0.10 mm (0.0039 inch)
80. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
a. Using a chisel and hammer, stake the drive pinion nut.
81. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST and a plastic hammer, install a new oil seal until its surface is flush with the differential carrier end.
SST 09608-32010
b. Coat the oil seal lip with MP grease.
Oil seal drive in depth: 0 ± 0.45 mm (0 ± 0.018 inch)
82. INSTALL FRONT DIFFERENTIAL TUBE ASSY
a. Remove the any oil FIPG material and be careful not to drop oil on the contact surfaces of the differential and clutch case.
b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.
c. Apply FIPG to the differential, as shown.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
HINT: Install the differential tube within 10 minutes after applying FIPG.
d. Install the differential tube to the differential.
e. Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
f. Apply adhesive to 2 to 3 threads of the bolts end.
Adhesive: Part No. 08833-00070, THREE BOND 1281 or equivalent
g. Install the 4 bolts.
Torque: 110 Nm (1,120 kgf-cm, 81 ft. lbs.)
83. INSTALL DIFFERENTIAL CARRIER ASSY FRONT
a. Install the No.1 mounting support with the 3 bolts.
Torque: 186 Nm (1,900 kgf-cm, 137 ft. lbs.)
b. Install the No.2 mounting support with the 2 bolts.
Torque: 160 Nm (1,630 kgf-cm, 118 ft. lbs.)
c. Install the front differential support No.3 with the 2 bolts.
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
d. Support the front differential with a jack.
e. Install the 2 front mounting bolts and nuts.
Torque: 137 Nm (1,400 kgf-cm, 101 ft. lbs.)
f. Install the front differential mount nuts No.1.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)
g. Install the front differential breather tube bracket with a bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
h. Lower the jack.
84. INSTALL FRONT DRIVE SHAFT ASSY LH
85. INSTALL FRONT DRIVE SHAFT ASSY RH
HINT: Install the RH side by the same procedures with the LH side.
86. INSTALL FRONT AXLE ASSY LH
87. INSTALL FRONT AXLE ASSY RH
HINT: Install the RH side by the same procedures with the LH side.
88. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
89. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT: Install the RH side by the same procedures with the LH side.
90. INSTALL TIE ROD END SUB-ASSY LH
91. INSTALL TIE ROD END SUB-ASSY RH
HINT: Install the RH side by the same procedures with the LH side.
92. INSTALL FRONT STABILIZER LINK ASSY LH
93. INSTALL FRONT STABILIZER LINK ASSY RH
HINT: Install the RH side by the same procedures with the LH side.
94. INSTALL FRONT AXLE HUB LH NUT
95. INSTALL FRONT AXLE HUB RH NUT
HINT: Install the RH side by the same procedures with the LH side.
96. INSPECT BEARING BACKLASH
97. INSPECT AXLE HUB DEVIATION
98. INSTALL FRONT AXLE HUB GREASE CAP LH
99. INSTALL FRONT AXLE HUB GREASE CAP RH
HINT: Install the RH side by the same procedures with the LH side.
100. INSTALL SPEED SENSOR FRONT LH
101. INSTALL SPEED SENSOR FRONT RH
HINT: Install the RH side by the same procedures with the LH side.
102. INSTALL PROPELLER SHAFT ASSY FRONT
103. REFILL DIFFERENTIAL OIL
104. INSPECT AND ADJUST DIFFERENTIAL OIL
105. INSTALL ENGINE UNDER COVER ASSY REAR
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
106. INSTALL ENGINE UNDER COVER SUB-ASSY NO.1
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
107. INSTALL FRONT WHEELS
Torque: 112 Nm (1,140 kgf-cm, 83 ft. lbs.)
108. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
109. CHECK ABS SPEED SENSOR SIGNAL