Reassembly
DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY
REASSEMBLY
1. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING
(a) Using SST and a press, install a new shaft RH bearing.
SST: 09223-00010
(b) Using a snap ring expander, install the snap ring.
2. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH
(a) Install the side gear shaft into the differential tube.
(b) Using snap ring pliers, install the snap ring.
3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a plastic hammer, install a new oil seal.
SST: 09223-15020
Oil seal drive in depth:
4.8 to 5.8 mm (0.1890 to 0.2284 in.)
(b) Coat the oil seal lip with MP grease.
4. INSTALL FRONT DIFFERENTIAL CASE
(a) Install the 2 proper thrust washers onto the 2 side gears.
HINT: Using the table below, select the thrust washer which will ensure that the backlash is within the specifications.
(b) Install the 2 side gears, 2 side gear thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft into the differential case assembly.
HINT: Align the holes of the differential case assembly and pinion shaft.
(c) Measure the side gear backlash.
(1) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case assembly.
Backlash:
0 to 0.15 mm (0 to 0.0059 in.)
If the backlash is not within the specification, install 2 side gear thrust washers with a different thickness.
(d) Using a pin punch and hammer, install the straight pin through the differential case assembly and hole of the pinion shaft.
(e) Stake the differential case assembly.
5. 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 take the ring gear out of the boiling water.
(d) After any moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case.
(e) Align the matchmarks on the ring gear and differential case assembly.
(f) After the ring gear has cooled sufficiently, tighten the ring gear 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-lbf)
6. INSTALL FRONT DIFFERENTIAL CASE BEARING
(a) Using SST and a press, install the 2 differential case bearings (inner) into the differential case.
SST: 09950-60010
09951-00520
09951-00610
SST: 09950-70010
09951-07150
7. INSTALL FRONT DIFFERENTIAL CASE BEARING
HINT: When replacing the 2 differential case bearings, fit 2 of the thinnest new washers to each bearing and when reusing the bearings, fit washers of the same thickness as those removed.
(a) Using SST and a press, install the case bearing (outer) race onto the differential case bearing retainer assembly (RH side).
SST: 09950-60020
09951-00810
SST: 09950-70010
09951-07150
(b) Install a new plate washer to the side bearing retainer (LH side).
SST: 09950-60020
09951-00810
SST: 09950-70010
09951-07150
8. INSTALL FRONT BEARING OUTER RACE
(a) Using SST, install the tapered roller bearings (outer) FR.
SST: 09950-00020
09951-00680
09951-00890
(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
09951-00680
09951-00890
9. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Install the washer onto the drive pinion.
HINT: First, fit a washer of the same thickness as the removed washer, then after checking the tooth contact pattern, replace the washer with one of a differential thickness if necessary.
(b) Using SST and a press, install the front bearing onto the drive pinion.
SST: 09506-30012
10. 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.
(e) Using SST to hold the companion flange, tighten the nut.
SST: 09330-00021
09330-00030
Torque: 370 Nm (3,770 kgf-cm, 273 ft-lbf)
NOTE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.
(f) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting):
11. INSTALL REAR DIFFERENTIAL CASE
12. 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-lbf)
(b) Using SST and a dial indicator, measure the ring gear backlash.
SST: 09564-32011
Backlash:
0.11 to 0.18 mm (0.0043 to 0.0071 in.)
(c) If it is not within the specification, adjust it by either increasing or decreasing the thickness of the washers on both sides by an equal amount.
HINT: There should be no clearance between the plate washer and differential case.
Make sure that there is ring gear backlash.
Washer thickness
13. 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 to 0.63 N*m (2 to 6 kgf*cm, 1.8 to 5.6 in.*lbf)
14. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Remove the side bearing retainer and differential case assembly.
(b) Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead.
(c) Install the differential case assembly and side bearing retainer.
Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)
(d) Hold the companion flange firmly and rotate the ring gear in both directions.
(e) Remove the differential case, side bearing retainer and differential case assembly.
(f) Inspect the tooth contact pattern.
If the teeth are not engaged properly, use the following chart to select the appropriate washer for correction.
Washer thickness
15. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
SST: 09330-00021
16. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03020
17. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
18. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
SST: 09556-22010
19. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new bearing spacer to the drive pinion.
20. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Install the front drive pinion rear tapered roller bearing.
21. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
22. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST and a hammer, install the oil seal.
SST: 09554-22010
Oil seal drive in depth:
3.9 to 4.8 mm (0.153 to 0.189 in.)
23. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR
(a) Using a steel plate and a press, install a new dust deflector.
NOTE: Do not damage the dust deflector.
24. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Place the 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-lbf)
25. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and side bearing retainer.
(b) Clean the contact 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 side bearing retainer within 10 minutes of applying FIPG.
(d) Install the side bearing retainer with the 10 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)
26. 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):
If the preload is greater than the specification, replace the bearing spacer.
If the preload is less than the specification, retighten the nut to 13 N*m (130 kgf*cm, 9 ft*lbf) a little at a time until the specified preload is reached.
Torque: 370 Nm (3,773 kgf-cm, 273 ft-lbf)
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repair the preload procedure. Do not loosen the nut to reduce the preload.
27. INSPECT TOTAL PRELOAD Front Differential Carrier Assembly
28. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION Front Differential Carrier Assembly
29. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY Front Differential Carrier Assembly
30. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
(a) Using a chisel and a hammer, stake the drive pinion nut.
31. 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 driven in depth:
-0.45 to 0.45 mm (-0.0177 to 0.0177 in.)
32. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY
(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential and clutch case.
(b) Clean the contact 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 of applying FIPG.
(d) Install the differential tube into the differential carrier assembly.
(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 each bolt end.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent
(g) Install the 4 bolts.
Torque: 110 Nm (1,122 kgf-cm, 81 ft-lbf) or less