Rear final drive (φ220 mm { 8.66 in }) (LSD) reassembly

1. Component views

Rear differential cage (φ220 mm {8.66 in}) （LSD）

Part name

  1. Flange nut
  2. Flange
  3. Oil seal
  4. Outer bearing inner race
  5. Outer bearing outer race
  6. Differential carrier
  7. Bearing cap
  8. Bolt
  9. Inner bearing outer race
  10. Collapsible distance piece
  11. Inner bearing inner race
  12. Adjust shim
  13. Drive pinion
  14. Ring gear
  15. differential cage assembly
  16. Adjust shim
  17. Side bearing inner race
  18. Side bearing outer race
  19. Bolt

1: 245 to 294 N・m { 25.0 to 30.0 kgf・m / 181 to 217 lb・ft }

8: 108 N・m { 11.0 kgf・m / 80 lb・ft }

19: 145 N・m { 14.8 kgf・m / 107 lb・ft }

Rear differential cage (φ220 mm {8.66 in}) （LSD）

Part name

  1. Screw
  2. Differential cage B
  3. Thrust washer
  4. spring plate
  5. spring plate
  6. Friction plate
  7. Friction disc
  8. Friction plate
  9. Friction disc
  10. pressure ring
  11. Side gear
  12. Pinion gear and spider
  13. Side gear
  14. pressure ring
  15. Friction disc
  16. Friction plate
  17. Friction disc
  18. Friction plate
  19. spring plate
  20. spring plate
  21. Thrust washer
  22. Differential cage A

2. Final drive safety information

When assembling, if nothing in particular is specified, refer to the following and apply or add differential oil.

Refer to "201.General Information 14B.Vehicle Information recommended fluids, lubricants and diesel fuels".

3. Differential cage reassembly

1) Measure the depth of the differential cage using a vernier caliper.

Standard: 80.58 mm { 3.172 in } A - B in the diagram

Standard: 10.58 mm { 0.417 in } C in the diagram

2) Measure the full length of the pressure ring, friction disc, and friction plate using a vernier caliper.

3) Measure the length between the plates on both ends of the V-groove.

Legend

a. Length between the plates on both ends of the V-groove (D)

4) Adjust the clearance between the friction disc and the friction plate.

5) Measure the dimensions of A, B, C, and D.

6) Measure the spring plate.

Standard: 1.75 mm { 0.069 in } ×4 pcs., E

7) Measure the thickness of the spring plate.

Standard: 1.75 mm { 0.069 in } ×2 pcs., F

8) Select the friction disc and friction plate so that the dimensions are as follows.

(A - B + C) - (D + E) = 0.06 to 0.20 mm {0.002 to 0.008 in}

Caution

  • The difference between the total dimensions of the left and right friction discs, friction plates, and spring plates must not be larger than 0.05 mm {0.002 in}.
Thickness of the friction disc and plate
1.65 mm { 0.065 in }
1.75 mm { 0.069 in }
1.85 mm { 0.073 in }

9) Adjust backlash of the side gear in the axial direction.

10) Measure the depth of the differential cage.

Standard: 82.03 mm { 3.230 in } F - B in the diagram

Standard: 12.03 mm { 0.474 in } G in the diagram

11) Install the following parts to the differential cage.

  • Side gear
  • Pinion
  • Spider
  • pressure ring
  • Thrust washer

Note

  • Press-fit the pressure ring in the axial direction toward the pinion shaft to eliminate clearance.
  • When installing the side gear to the pinion, eliminate the backlash.

12) Measure the dimension between the thrust washers at both ends.

Legend

a. Dimension between the thrust washers at both ends

Note

  • After measuring the dimension between the thrust washers at both ends, adjust it to be the following dimension.

((F - B) + G - H) = 0.05 to 0.2 mm {0.002 to 0.008 in}

Note

  • Select the appropriate thrust washer, so that the difference of the dimension from the rear surface of the pressure ring to the left and right thrust washers does not exceed the specified value.

Standard: 0.05 mm { 0.002 in } Left and right side

Thrust washer thicknesses
1.5 mm { 0.059 in }
1.6 mm { 0.063 in }
1.7 mm { 0.067 in }

13) Apply differential oil to the spider and each gear.

14) Install the thrust washer to the differential cage B.

15) Install the spring plate, friction disc, and friction plate to differential cage B.

Note

  • Install in the following order.
  • 2 spring plates
  • Friction plate
  • Friction disc
  • Friction plate
  • Friction disc

Note

  • Install the spring plate with the plate side facing toward the differential cage as shown in the following diagram.

Legend

  1. Friction plate
  2. spring plate
  3. Friction disc

16) Install the pressure ring to the differential cage B.

17) Install the side gear to differential cage B.

18) Install the drive pinion to differential cage B.

19) Install the pressure ring to the differential cage B.

20) Install the friction disc, friction plate and spring plate to differential cage B.

Note

  • Install in the following order.
  • Friction disc
  • Friction plate
  • Friction disc
  • Friction plate
  • 2 spring plates

21) Install the thrust washer to the differential cage B.

22) Install differential cage B to differential cage A based on the alignment marks.

Note

  • Tighten the screws evenly in a diagonal order.

23) Measure the starting torque of the side gear using the special tool.


SST: 5-8840-2381-0 - side gear holder

Standard: 29 to 45 N・m { 3.0 to 4.6 kgf・m / 21 to 33 lb・ft }

Legend

  1. 5-8840-2381-0

4. Final drive reassembly

1) Install the outer bearing outer race to the differential carrier using the special tool.


SST: 5-8840-2164-0 - bearing installer


SST: 5-8840-0007-0 - grip

Legend

  1. 5-8840-0007-0
  2. 5-8840-2164-0

2) Install the inner bearing outer race to the differential carrier using the special tool.


SST: 5-8840-2163-0 - bearing installer


SST: 5-8840-0007-0 - grip

Legend

  1. 5-8840-0007-0
  2. 5-8840-2163-0

3) Apply differential oil to the inner bearing inner race and outer bearing inner race.

4) Install the following parts to the differential carrier.

  • Inner bearing inner race
  • Outer bearing inner race
  • Special tool

Caution

  • Thoroughly clean the special tool before using it.


SST: 5-8840-2166-0 - gauge plate


SST: 5-8840-0129-0 - pilot


SST: 5-8840-0127-0 - stud & nut


SST: 5-8840-2085-0 - pilot

Tightening torque: 2.7 N・m { 0.3 kgf・m / 24 lb・in } Special tool nut

Legend

  1. 5-8840-0129-0
  2. 5-8840-2085-0
  3. 5-8840-2166-0
  4. 5-8840-0127-0

5) Clean the side bearing installation section.

6) Install the special tool and dial indicator to the differential carrier.


SST: 5-8840-0126-0 - dial indicator


SST: 5-8840-2166-0 - gauge plate


SST: 5-8840-2167-0 - disc 2pcs.required


SST: 5-8840-0128-0 - arbor

7) Install the bearing cap to the differential carrier.

Tightening torque: 108 N・m { 11.0 kgf・m / 80 lb・ft }

Legend

  1. 5-8840-0126-0
  2. 5-8840-2166-0
  3. 5-8840-2167-0
  4. 5-8840-0128-0

Note

  • The dial indicator scale display is in inches.

8) Set the dial indicator scale to 0.

9) Bring the dial indicator into contact with the arbor plunger section, then push the dial indicator down to the point where the needle rotates approximately halfway in the clockwise direction, and secure.

Legend

  1. 5-8840-0126-0
  2. 5-8840-0128-0
  3. Plunger (5-8840-0128-0)
  4. 5-8840-2166-0

10) Set the dial indicator scale to 0.

11) Place the end of the arbor plunger on top of the gauge plate.

12) Move the arbor back and forth, and verify the position where the dial indicator runout is largest.

13) Set the dial indicator scale to 0 at the position where the dial indicator runout is largest.

Note

  • Perform the above procedure again to confirm the 0 point.

14) Rotate the arbor and move the end of the plunger away from the gauge plate.

15) Record the value indicated on the dial indicator.

Legend

  1. Example: when the dial indicator reading numerical value is 0.085

16) Record the pinion depth code on the drive pinion upper section.

If the value is positive, the mesh depth is too large, so decrease the shim thickness.
If the value is negative, the mesh depth is too small, so increase the shim thickness.
0 indicates that no adjustment is required.

Ex: If the value is +2, the mesh depth is 0.02 mm {0.0008 in} too large, so decrease the shim thickness by 0.02 mm {0.0008 in}.
If the value is negative, perform the opposite.

17) Select the appropriate adjust shim based on the value read by the dial indicator and the drive pinion code.

Note

  • Select a shim from the following table.
Adjust shim selection table (mm {in}) No. 1
Dial indicator reading (in)
 Drive pinion depth code
10
 8
 6
 4
 2
 0
0.073





0.074





0.075





0.076




1.94
{0.0764}
0.077




1.96
{0.0772}
0.078


1.94
{0.0764}
 1.96
{0.0772}
 1.98
{0.0780}
0.079

1.94
{0.0764}
 1.96
{0.0772}
 1.98
{0.0780}
 2.00
{0.0787}
0.080
 1.94
{0.0764}
 1.96
{0.0772}
 1.98
{0.0780}
 2.00
{0.0787}
 2.02
{0.0795}
 2.04
{0.0803}
0.081
 1.96
{0.0772}
 1.98
{0.0780}
 2.00
{0.0787}
 2.02
{0.0795}
 2.04
{0.0803}
 2.06
{0.0811}
0.082
 1.98
{0.0780}
 2.00
{0.0787}
 2.02
{0.0795}
 2.04
{0.0803}
 2.06
{0.0811}
 2.08
{0.0819}
0.083
 2.00
{0.0787}
 2.02
{0.0795}
 2.04
{0.0803}
 2.06
{0.0811}
 2.08
{0.0819}
 2.10
{0.0827}
0.084
 2.04
{0.0803}
 2.06
{0.0811}
 2.08
{0.0819}
 2.10
{0.0827}
 2.12
{0.0835}
 2.14
{0.0843}
0.085
 2.06
{0.0811}
 2.08
{0.0819}
 2.10
{0.0827}
 2.12
{0.0835}
 2.14
{0.0843}
 2.16
{0.0850}
0.086
 2.08
{0.0819}
 2.10
{0.0827}
 2.12
{0.0835}
 2.14
{0.0843}
 2.16
{0.0850}
 2.18
{0.0858}
0.087
 2.12
{0.0835}
 2.14
{0.0843}
 2.16
{0.0850}
 2.18
{0.0858}
 2.20
{0.0866}
 2.22
{0.0874}
0.088
 2.14
{0.0843}
 2.16
{0.0850}
 2.18
{0.0858}
 2.20
{0.0866}
 2.22
{0.0874}
 2.24
{0.0882}
0.089
 2.16
{0.0850}
 2.18
{0.0858}
 2.20
{0.0866}
 2.22
{0.0874}
 2.24
{0.0882}
 2.26
{0.0890}
0.090
 2.18
{0.0858}
 2.20
{0.0866}
 2.22
{0.0874}
 2.24
{0.0882}
 2.26
{0.0890}
 2.28
{0.0898}
0.091
 2.20
{0.0866}
 2.24
{0.0882}
 2.26
{0.0890}
 2.28
{0.0898}
 2.30
{0.0906}
 2.32
{0.0913}
0.092
 2.24
{0.0882}
 2.26
{0.0890}
 2.28
{0.0898}
 2.30
{0.0906}
 2.32
{0.0913}
 2.34
{0.0921}
0.093
 2.26
{0.0890}
 2.28
{0.0898}
 2.30
{0.0906}
 2.32
{0.0913}
 2.34
{0.0921}
 2.36
{0.0929}
0.094
 2.28
{0.0898}
 2.30
{0.0906}
 2.32
{0.0913}
 2.34
{0.0921}
 2.36
{0.0929}
0.095
 2.32
{0.0913}
 2.34
{0.0921}
 2.36
{0.0929}


0.096
 2.34
{0.0921}
 2.36
{0.0929}



0.097
 2.36
{0.0929}




Adjust shim selection table (mm {in}) No. 2
Dial indicator reading (in)
 Drive pinion depth code
0
 -2
 -4
 -6
 -8
 -10
0.073



1.94
{0.0764}
 1.96
{0.0772}
0.074


1.94
{0.0764}
 1.96
{0.0772}
 1.98
{0.0780}
0.075

1.94
{0.0764}
 1.96
{0.0772}
 1.98
{0.0780}
 2.00
{0.0787}
0.076
 1.94
{0.0764}
 1.96
{0.0772}
 1.98
{0.0780}
 2.00
{0.0787}
 2.02
{0.0795}
 2.04
{0.0803}
0.077
 1.96
{0.0772}
 1.98
{0.0780}
 2.00
{0.0787}
 2.02
{0.0795}
 2.04
{0.0803}
 2.06
{0.0811}
0.078
 1.98
{0.0780}
 2.00
{0.0787}
 2.02
{0.0795}
 2.04
{0.0803}
 2.06
{0.0811}
 2.08
{0.0819}
0.079
 2.00
{0.0787}
 2.02
{0.0795}
 2.04
{0.0803}
 2.06
{0.0811}
 2.08
{0.0819}
 2.10
{0.0827}
0.080
 2.04
{0.0803}
 2.06
{0.0811}
 2.08
{0.0819}
 2.10
{0.0827}
 2.12
{0.0835}
 2.14
{0.0843}
0.081
 2.06
{0.0811}
 2.08
{0.0819}
 2.10
{0.0827}
 2.12
{0.0835}
 2.14
{0.0843}
 2.16
{0.0850}
0.082
 2.08
{0.0819}
 2.10
{0.0827}
 2.12
{0.0835}
 2.14
{0.0843}
 2.16
{0.0850}
 2.18
{0.0858}
0.083
 2.10
{0.0827}
 2.12
{0.0835}
 2.14
{0.0843}
 2.16
{0.0850}
 2.18
{0.0858}
 2.20
{0.0866}
0.084
 2.14
{0.0843}
 2.16
{0.0850}
 2.18
{0.0858}
 2.20
{0.0866}
 2.22
{0.0874}
 2.24
{0.0882}
0.085
 2.16
{0.0850}
 2.18
{0.0858}
 2.20
{0.0866}
 2.22
{0.0874}
 2.24
{0.0882}
 2.26
{0.0890}
0.086
 2.18
{0.0858}
 2.20
{0.0866}
 2.22
{0.0874}
 2.24
{0.0882}
 2.26
{0.0890}
 2.28
{0.0898}
0.087
 2.22
{0.0874}
 2.24
{0.0882}
 2.26
{0.0890}
 2.28
{0.0898}
 2.30
{0.0906}
 2.32
{0.0913}
0.088
 2.24
{0.0882}
 2.26
{0.0890}
 2.28
{0.0898}
 2.30
{0.0906}
 2.32
{0.0913}
 2.34
{0.0921}
0.089
 2.26
{0.0890}
 2.28
{0.0898}
 2.30
{0.0906}
 2.32
{0.0913}
 2.34
{0.0921}
 2.36
{0.0929}
0.090
 2.28
{0.0898}
 2.30
{0.0906}
 2.32
{0.0913}
 2.34
{0.0921}
 2.36
{0.0929}
0.091
 2.32
{0.0913}
 2.34
{0.0921}
 2.36
{0.0929}


0.092
 2.34
{0.0921}
 2.36
{0.0929}



0.093
 2.36
{0.0929}




0.094





0.095





0.096





0.097





Note

  • When ordering shims, check the shim thickness in the above table and identify the part numbers on the part catalog.

18) Install the shim and inner bearing inner race to the drive pinion using the special tool and press.

Caution

  • Do not apply force to the roller gauge.


SST: 9-8522-1165-0 - pinion bearing installer

Legend

  1. 9-8522-1165-0

19) Install the collapsible distance piece to the drive pinion.

Caution

  • Do not reuse the collapsible distance piece.

20) Install the drive pinion to the differential carrier.

21) Apply the grease to the oil seal.

22) Install the oil seal and outer bearing inner race to the differential carrier using the special tool.

Caution

  • Do not reuse the oil seal.


SST: 5-8840-2165-0 - oil seal installer

Legend

  1. 5-8840-2165-0

23) Apply differential oil to the threaded portion of the drive pinion.

24) Temporarily tighten the flange to the drive pinion using the special tool.

Caution

  • Do not reuse the flange nut.


SST: 5-8840-0133-0（J-8614-11） - flange holder

Legend

  1. 5-8840-0133-0

25) Measure the pinion bearing preload.

Standard: 0.7 to 1.3 N・m { 0.1 to 0.1 kgf・m / 6 to 12 lb・in } Starting torque

Caution

  • If the pinion bearing preload is outside the specified range, adjust by further tightening or loosening the flange nut.

Tightening torque: 245 to 294 N・m { 25.0 to 30.0 kgf・m / 181 to 217 lb・ft }

26) Stake the flange nut in 2 locations using the special tool and hammer.

Caution

  • When staking, rotate the nut to confirm the correct preload.


SST: 5-8840-2293-0 - end nut lock punch

Legend

  1. 5-8840-2293-0

Standard value

a: 1.5 mm { 0.06 in } or less

27) Measure the pinion bearing preload.

Standard: 0.7 to 1.3 N・m { 0.1 to 0.1 kgf・m / 6 to 12 lb・in } Starting torque

28) Install the side bearing inner race to the differential cage using the special tool.


SST: 5-8840-2162-0 - side bearing installer


SST: 5-8840-0007-0 - grip

Legend

  1. 5-8840-0007-0
  2. 5-8840-2162-0

29) Install the side bearing outer race to the differential cage.

30) Install the differential cage to the differential carrier.

31) Insert the 2 feeler gauges so that the backlash between the left and right side bearing outer races and the differential carrier is 0.

Note

  • Securely insert the feeler gauge all the way to the bottom of the bearing.

32) Install the special tool to the differential carrier.

Note

  • Install the special tool so that it makes contact perpendicularly with the gear teeth of the ring gear.


SST: 5-8840-0126-0 - dial indicator

Legend

  1. 5-8840-0126-0

33) Change the left and right feeler gauge thicknesses and adjust the backlash.

Standard: 0.15 to 0.20 mm { 0.006 to 0.008 in }

The dial indicator scale display is in inches.

34) Select a shim based on the thickness of the feeler gauge.

Note

  • Select a shim 0.05 mm {0.0020 in} thicker than the feeler gauge.

Caution

  • Do not reuse the shim.

35) Remove the differential cage from the differential carrier.

36) Remove the side bearing outer race from the differential cage.

Caution

  • When removing the bearings, keep them organized so the combinations of the left/right installation positions and bearing race are not mixed up.

37) Remove the side bearing inner race from the differential cage using the special tool.


SST: 9-8521-0152-2 - bearing remover


SST: 5-8840-2863-0 - driver tool set

38) Install the shim and side bearing inner race to the differential cage using the special tool.


SST: 5-8840-2162-0 - side bearing installer


SST: 5-8840-0007-0 - grip

Legend

  1. 5-8840-0007-0
  2. 5-8840-2162-0

39) Install the side bearing outer race to the differential cage.

40) Install the differential cage to the differential carrier.

41) Install the bearing cap to the differential carrier.

Note

  • Install according to the alignment marks applied during disassembly.

Tightening torque: 108 N・m { 11.0 kgf・m / 80 lb・ft }

Legend

  1. Alignment mark

42) Measure the runout of the ring gear using the dial gauge.

Limit: 0.05 mm { 0.002 in } or less

Note

  • Measure the runout of the ring gear at its rear surface.

43) Clean the gear teeth of the ring gear and of the drive pinion.

44) Apply red lead primer to the gear teeth of the ring gear.

Note

  • Apply to both surfaces of 7 to 8 gear teeth.

45) Slightly move the ring gear while holding the drive pinion by hand, and inspect the tooth contact of the ring gear and drive pinion.

Caution

  • Refer to the following diagram to adjust the positions of the ring gear and drive pinion if the tooth contact of the ring gear and drive pinion is found to be incorrect as a result of the inspection.

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