REAR DIFFERENTIAL ASSEMBLY

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  Warning
  • The engine stand is equipped with a self-lock mechanism, however, if the rear differential is in a tilted condition, the self-lock mechanism could become inoperative. If the rear differential unexpectedly rotates it could cause injury, therefore do not maintain the rear differential in a tilted condition. When turning the rear differential, grasp the rotation handle firmly.

  Note
  • Clean away the old sealant before applying the new sealant.
  • Install the rear cover before the applied sealant starts to harden.
  • Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified oil.

1. Assemble in the order indicated in the table.

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1 | Gear case
2 | Side bearing inner race (See Side Bearing Inner Race Assembly Note.)
3 | Thrust washer (See Thrust washer Assembly Note.)
4 | Side gear
5 | Pinion gear
6 | Pinion shaft
7 | Knock pin
8 | Ring gear (See Ring Gear Assembly Note.)
9 | Differential carrier
10 | Bearing outer race (See Bearing Outer Race Assembly Note.)
11 | Spacer (See Spacer, Bearing Inner Race Assembly Note.)
12 | Bearing inner race (rear bearing) (See Spacer, Bearing Inner Race Assembly Note.)
13 | Bearing inner race (front bearing) (See Spacer, Bearing Inner Race Assembly Note.)
14 | Collapsible spacer
15 | Drive pinion
16 | Locknut (See Locknut Assembly Note.)
17 | Washer
18 | Adjusting shim (LH) (See Adjusting Shim Assembly Note.)
19 | Spacer
20 | Side bearing outer race
21 | Rear differential component
22 | Adjusting shim (RH) (See Adjusting Shim Assembly Note.)
23 | Bearing cap (See Bearing Cap Assembly Note.)
24 | Rear cover (See Rear Cover Assembly Note.)
25 | Differential oil temperature sensor
26 | Oil seal (See Oil Seal Assembly Note.)

Side Bearing Inner Race Assembly Note

  Caution
  • Do not mix up the left and right side bearing inner races.

1. Press the side bearing inner races into the gear case using the SSTs.

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Thrust washer Assembly Note

1. Assemble the side gears, thrust washers and pinion gears to the gear case, then assemble the knock pin.

2. After assembling the knock pin, make a crimp so that the pin will not come out of the gear case.

3. Set a dial gauge to the pinion gear as indicated in the figure.

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4. Secure one of the side gears.

5. Move the pinion gear and measure the backlash at the end of the pinion gear.

  • If the backlash exceeds the standard, use the thrust washers to adjust.

  Rear differential backlash of pinion gear and side gear

  0.1 mm {0.004 in} or less

Thrust washer thickness

Identification mark | Thickness
--- | ---
0 | 2.0 mm {0.079 in}
1 | 2.1 mm {0.083 in}
2 | 2.2 mm {0.086 in}
05 | 2.05 mm {0.081 in}
15 | 2.15 mm {0.084 in}

Ring Gear Assembly Note

  Caution
  • The differential gear and ring gear could be damaged if the ring gear is installed with old thread-locking compound remaining on the bolt threads. Before installing the ring gear, completely remove the old thread-locking compound from the bolt threads.

1. Apply a small amount of thread-locking compound to each of points A on the back of the ring gear, and bolt thread areas B (around the entire ring).

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  Application amount

  Back of ring gear:
  Approx. 0.4 ml {0.4 cc, 0.02 cu in}
  Ring gear bolt thread points:
  Approx. 0.4 ml {0.4 cc, 0.02 cu in}
  (0.04 ml {0.04 cc, 0.002 cu in} to each point)

2. Align the marks placed on the ring gear case at the time of disassembly and tighten the bolts in diagonal order.

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  Tightening torque

  68.6—83.3 N·m {7.00—8.49 kgf·m, 50.6—61.4 ft·lbf}

Bearing Outer Race Assembly Note

1. Press in the bearing outer race using the SSTs and a press.

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Spacer, Bearing Inner Race Assembly Note

Pinion height adjustment

  Note
  • Use the same spacer.
  • Install the spacer with the chamfer on the SST side.

1. Assemble the spacer, the bearing inner race (rear bearing), and the SST O-ring to the SST (49 8531 565) as shown in the figure.

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2. Insert the set assembled in Step 1 to the differential gear from the rear.

3. Assemble the bearing inner race (front bearing), SST (49 G027 005), companion flange, washer, and locknut from the front of the differential gear.

4. Tighten the locknut to the extent that the SST (49 8531 565) can be turned by hand.

5. Place the SST (49 0305 555) on top of the SST (49 8531 565).

6. Place the SST on the surface plate and set the dial indicator to zero.

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7. Set the SST as shown in the figure.

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8. Place the measuring probe of the dial indicator so that it contacts the place where the side bearing is installed in the carrier. Then measure the left and right side of the lower position.

9. Add the two (left and right) values obtained by the measurements taken in Step 8 and then divide the total by 2. From this result, subtract the result obtained by dividing the number inscribed on the end surface of the drive pinion by 100. (If there is no figure inscribed, use 0.) This is the pinion height adjustment value.

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  Rear differential pinion height

  –0.032—0.032 mm {–0.0012—0.0012 in}

  Note
  • For example, the measured results obtained at Step 8 and 9 are 0.06 mm {0.003 in} and 0.04 mm {0.002 in}, and the figure inscribed on the end of the drive pinion is 2:
  ((0.06 mm {0.003 in}+ 0.04 mm {0.002 in}) / 2) – (2/100) = 0.03 mm {0.001 in} (pinion height adjustment value)
  Replace with a spacer 0.03 mm {0.001 in} thicker than the currently used one. Spacer thickness is set at 0.015 mm {0.0006 in} increments, therefore select the closest spacer thickness and assemble.
  • Install the spacer with the chamfer on the SST side.

Spacer thickness

Identification mark | Thickness (mm {in}) | Identification mark | Thickness (mm {in})
--- | --- | --- | ---
08 | 3.08 {0.1213} | 29 | 3.29 {0.1295}
09 | 3.095 {0.1219} | 30 | 3.305 {0.1301}
11 | 3.11 {0.1224} | 32 | 3.32 {0.1307}
12 | 3.125 {0.1230} | 33 | 3.335 {0.1313}
14 | 3.14 {0.1236} | 35 | 3.35 {0.1319}
15 | 3.155 {0.1242} | 36 | 3.365 {0.1325}
17 | 3.17 {0.1248} | 38 | 3.38 {0.1331}
18 | 3.185 {0.1254} | 39 | 3.395 {0.1337}
20 | 3.20 {0.1260} | 41 | 3.41 {0.1343}
21 | 3.215 {0.1266} | 42 | 3.425 {0.1348}
23 | 3.23 {0.1272} | 44 | 3.44 {0.1354}
24 | 3.245 {0.1278} | 45 | 3.455 {0.1360}
26 | 3.26 {0.1283} | 47 | 3.47 {0.1366}
27 | 3.275 {0.1289} | — | —

10. Assemble the spacer selected for the pinion height adjustment to the drive pinion.

11. Press the bearing inner race (rear bearing) into the drive pinion using the SSTs and a press.

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Locknut Assembly Note

Drive pinion preload adjustment

1. Apply differential oil to a new locknut.

2. Assemble a new collapsible spacer, bearing inner race (front bearing), spacer and locknut to the drive pinion, and temporarily tighten the locknut.

3. Turn the serrated part of the drive pinion by hand to seat the bearing.

4. Tighten the locknut temporarily tightened in Step 1 from the lower limit of the specified tightening torque using the SSTs, and make this the specified preload.

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  • If the specified preload cannot be obtained within the specified tightening torque, replace the collapsible spacer and inspect again.

  Tightening torque

  240—755 N·m {24.5—76.9 kgf·m, 177—556 ft·lbf}

  Rear differential drive pinion preload

  1.3—1.8 N·m {14—18 kgf·cm, 12—15 in·lbf}

5. Crimp the locknut using a chisel and hammer.

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Adjusting Shim Assembly Note

1. Assemble the differential carrier to the SSTs.

2. Assemble the spacer to the differential carrier.

3. Stack the side bearing outer race and gear case component on the surface plate as indicated in the figure, and measure the height using a caliper and a ruler. This is value A.

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4. Measure the width of the installed differential in the differential carrier with the spacer installed. This is value B.

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5. The combined thickness of the left and right adjusting shims is obtained by the following formula.

C1= B – A + 0.15 mm {0.006 in}

C2= B – A + 0.44 mm {0.017 in}

6. If the combined thickness of the previously installed adjusting shims is between C1 and C2, use the shims as they are.

7. If the combined thickness of the previously installed adjusting shims is not between C1 and C2, or if the adjusting shims have to be replaced, select two appropriate adjusting shims from the table below.

Adjusting shim thickness

Identification mark | Thickness (mm {in}) | Identification mark | Thickness (mm {in})
--- | --- | --- | ---
350 | 3.50 {0.137} | 410 | 4.10 {0.161}
355 | 3.55 {0.139} | 415 | 4.15 {0.163}
360 | 3.60 {0.141} | 420 | 4.20 {0.165}
365 | 3.65 {0.143} | 425 | 4.25 {0.167}
370 | 3.70 {0.145} | 430 | 4.30 {0.169}
375 | 3.75 {0.147} | 435 | 4.35 {0.171}
380 | 3.80 {0.149} | 440 | 4.40 {0.173}
385 | 3.85 {0.151} | 445 | 4.45 {0.175}
390 | 3.90 {0.153} | 450 | 4.50 {0.177}
395 | 3.95 {0.155} | 455 | 4.55 {0.179}
400 | 4.00 {0.157} | 460 | 4.60 {0.181}
405 | 4.05 {0.159} | — | —

  Caution
  • If adjusting shims are to be reused, do not mix up the left and right shims.
  • Do not mix up the left and right side bearing outer races and spacers.

8. Assemble the selected adjusting shims to the differential carrier ring gear side, and the spacer to the opposite side.

9. Assemble the differential and bearing outer race to the differential carrier.

10. Tap the selected adjusting shim between the spacer and the bearing race with a plastic hammer as shown in the figure.

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11. Align the bearing cap alignment marks to assemble the bearing cap, and temporarily tighten the bolts.

12. Place the dial indicator so that the measuring probe contacts the top surface of one of the ring gear teeth perpendicularly.

13. Secure the drive pinion and measure the backlash from when the ring gear moved.

  Rear differential backlash of drive pinion and ring gear

  Standard: 0.09—0.11 mm {0.003—0.004 in}
  Minimum value: 0.05 mm {0.002 in}

  Note
  • Measure the backlash at 4 locations around the ring gear. Make sure one of the 4 locations is within specification, and the minimum value for the 4 locations is 0.5 mm {0.002 in}or less.

14. If the backlash is not within the specification, adjust the gear case component by moving it in the axial direction.

  Note
  • When moving the gear case component in the axial direction, replace the adjusting shims. If the adjusting shim on the right side is replaced with one that is 0.05 mm {0.002 in}thicker, replace the one on the left with one that is 0.05 mm {0.002 in}thinner.

Bearing Cap Assembly Note

1. Align the bearing cap alignment marks to assemble the bearing cap.

  Tightening torque

  38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

2. Inspect the drive pinion and ring gear teeth contact points.

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  (1) Coat both surfaces of the ring gear uniformly with a thin red lead coating.

  (2) While rotating the ring gear back and forth by hand, rotate the drive pinion several times and inspect the tooth contact.

  (3) Inspect the tooth contacts in four locations around the ring gear, and check that the tooth contacts showing the red lead coating are the same as the pattern indicated in the figure.
    • If the tooth contact is good, wipe off the red lead coating.
    • If it is not good, adjust the pinion height, then adjust the backlash.

  (4) If toe and flank contact appears as shown in the figure, replace the spacer with a thinner one, and move the drive pinion outward.

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  (5) If heel and face contact appears as indicated in the figure, replace the spacer with a thicker one and move the drive the pinion inward.

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Rear Cover Assembly Note

  Caution
  • Clean away the old sealant before applying the new sealant.
  • Install the rear cover before the applied sealant starts to harden.
  • Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified oil.

1. Clean the alignment surface of the carrier and rear cover, and apply a thin coat of sealant.

2. Install the rear cover.

  Tightening torque

  15.7—22.6 N·m {1.61—2.30 kgf·m, 11.6—16.6 ft·lbf}

Oil Seal Assembly Note

1. Apply differential oil to the new oil seal lip.

2. Assemble the oil seal using the SSTs.

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