1. Component views
Rear differential cage (φ220 mm {8.66 in})
Part name
- Pinion gear
- Side gear thrust washer
- Side gear
- Cross pin
- Lock pin
- Ring gear
- Bolt
- Differential cage
Tightening torque
7: 145 N・m { 14.8 kgf・m / 107 lb・ft }
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) Install the side gear and side gear thrust washer to the differential cage.
2) Install the pinion gear to the differential cage.
3) While turning both pinion gears in the same direction, engage them with the side gear and install the pinion gears.
4) Install the cross pin to the differential cage.
Note
- Align the lock pin holes of the cross pin and differential cage and install.
5) Install the side gear and side gear thrust washer to differential cage B.
6) Measure the backlash of the pinion gear using a dial gauge.
Caution
- If the backlash is outside the specified range, change the thrust washer thickness and adjust.
Standard: 0.13 to 0.18 mm { 0.005 to 0.007 in } Backlash
| Thrust washer thicknesses |
| 0.80 mm { 0.031 in } |
| 0.90 mm { 0.035 in } |
| 1.00 mm { 0.039 in } |
| 1.10 mm { 0.043 in } |
| 1.20 mm { 0.047 in } |
| 1.30 mm { 0.051 in } |
7) Install the lock pin to the differential cage.
Caution
- Securely stake the lock pin so that it does not come out.
Legend
- Staked section
- Lock pin
8) Apply LOCTITE 263 to the threaded portion of the bolts and the ring gear threaded holes.
9) Install the ring gear to the differential cage.
Note
- Apply LOCTITE 263 to the threaded portion of the bolts from the end toward the center in a straight line.
Caution
- If using any adhesive other than LOCTITE 263, the bolts may be loosened or broken.
- Do not reuse the bolts, when replacing the ring gear.
- Replace the ring gear and drive pinion as a set.
Ring gear bolt tightening order
Tightening torque: 145 N・m { 14.8 kgf・m / 107 lb・ft }
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
- 5-8840-0007-0
- 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
- 5-8840-0007-0
- 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
- 5-8840-0129-0
- 5-8840-2085-0
- 5-8840-2166-0
- 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
- 5-8840-0126-0
- 5-8840-2166-0
- 5-8840-2167-0
- 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
- 5-8840-0126-0
- 5-8840-0128-0
- Plunger (5-8840-0128-0)
- 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
- 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.
| 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} |
|||||
| 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
- 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
- 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
- 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
- 5-8840-2293-0
Standard value
a: 1.5 mm or less { 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
- 5-8840-0007-0
- 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
- 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
- 5-8840-0007-0
- 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
- Alignment mark
42) Measure the runout of the ring gear using the dial gauge.
Limit: 0.05 mm or less { 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.
