REAR DIFFERENTIAL ASSEMBLY

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Caution
•  To prevent silicone sealant from hardening, adhere the rear cover to the differential carrier within 3 min after silicone sealant is applied.
•  Allow the sealant to set at least 30 min or more after installation before filling the differential with differential oil.

1.  Assemble in the order indicated in the table.

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1
Differential carrier
2
Rear bearing outer race
(See Rear Bearing Outer Race, Front Bearing Outer Race Assembly Note.)
3
Front bearing outer race
(See Rear Bearing Outer Race, Front Bearing Outer Race Assembly Note.)
4
Drive pinion
5
Spacer
(See Spacer, Rear Bearing Assembly Note.)
6
Rear bearing
(See Spacer, Rear Bearing Assembly Note.)
7
Collapsible spacer
8
Front bearing
9
Spacer
10
Oil seal (companion flange)
(See Oil Seal (Companion Flange), Drive Pinion Component, Locknut Assembly Note.)
11
Drive pinion component
(See Oil Seal (Companion Flange), Drive Pinion Component, Locknut Assembly Note.)
12
Companion flange
13
Washer
14
Locknut
(See Oil Seal (Companion Flange), Drive Pinion Component, Locknut Assembly Note.)
15
Differential gear case
16
Thrust washer
(See Thrust Washer, Spring Pin Assembly Note.)
17
Side gear
18
Washer
19
Pinion gear
20
Pinion shaft
21
Spring pin
(See Thrust Washer, Spring Pin Assembly Note.)
22
Side bearing
(See Side Bearing Assembly Note.)
23
Ring gear
(See Ring Gear Assembly Note.)
24
Side bearing outer race
25
Spacer
(See Spacer, Adjustment Shim, Differential Gear Case Component Assembly Note.)
26
Adjustment shim
(See Spacer, Adjustment Shim, Differential Gear Case Component Assembly Note.)
27
Differential gear case component
(See Spacer, Adjustment Shim, Differential Gear Case Component Assembly Note.)
28
Baffle plate
29
Rear cover
(See Rear Cover Assembly Note.)
30
Breather
31
Oil seal (side gear)
(See Oil Seal (Side Gear) Assembly Note.)


Rear Bearing Outer Race, Front Bearing Outer Race Assembly Note

Press fit the bearing outer race into the differential carrier using the SSTs, a press, and a steel plate.
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Spacer, Rear Bearing Assembly Note

1.  Choose a new spacer with the same thickness as the assembled spacer.

Spacer table

Determination mark

Thickness (mm {in})

Determination mark

Thickness (mm {in})
08
3.080 {0.1213}
29
3.290 {0.1295}
09
3.095 {0.1219}
30
3.305 {0.1301}
11
3.110 {0.1224}
32
3.320 {0.1307}
12
3.125 {0.1230}
33
3.335 {0.1313}
14
3.140 {0.1236}
35
3.350 {0.1319}
15
3.155 {0.1242}
36
3.365 {0.1325}
17
3.170 {0.1248}
38
3.380 {0.1331}
18
3.185 {0.1254}
39
3.395 {0.1337}
20
3.200 {0.1260}
41
3.410 {0.1343}
21
3.215 {0.1266}
42
3.425 {0.1348}
23
3.230 {0.1272}
44
3.440 {0.1354}
24
3.245 {0.1278}
45
3.455 {0.1360}
26
3.260 {0.1283}
47
3.470 {0.1366}
27
3.275 {0.1289}
—
—

2.  Assemble the spacer with the chamfer facing the pinion gear side.

3.  Press fit the rear bearing into the drive pinion using the SST and a press.

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Oil Seal (Companion Flange), Drive Pinion Component, Locknut Assembly Note

Note
•  Perform preload adjustment with the oil seal uninstalled.

1.  Adjust the drive pinion preload using the following procedures.

(1)  Assemble the following parts to the drive pinion.
•  New collapsible spacer
•  Front bearing
•  New spacer
•  Companion flange
•  New washer
•  New locknut
(2)  Turn the serrated part of the drive pinion by hand to seat the bearing.
(3)  Tighten the locknut assembled in Step 1 from the lower limit of the specified tightening torque using the SST, and obtain the specified preload. Record the tightening torque at this time.
Tightening torque
127—362 N·m {13—36 kgf·m, 94—266 ft·lbf}
Drive pinion preload
0.8—1.2 N·m {8.2—12 kgf·cm, 7.1—10 in·lbf}
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•  If the specified preload cannot be obtained within the specified tightening torque, replace the collapsible spacer with a new one and adjust again.
(4)  Remove the locknut, washer, and companion flange.

2.  Apply differential oil to the lip of a new oil seal.

3.  Assemble the oil seal using the SSTs and a hammer.

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4.  Tighten a new locknut and new washer using the SST with the torque recorded at the drive pinion preload adjustment.

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Thrust Washer, Spring Pin Assembly Note

1.  Assemble the following parts to the differential gear case.

•  Side gear
•  Thrust washer
•  Pinion gear
•  Washer
•  Pinion shaft

2.  Align the differential gear case and pinion shaft pin holes.

3.  Tap the spring pin in using a pin punch and a hammer.

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4.  Install a dial gauge with the measuring probe of the dial gauge attached perpendicularly to the end of one of the pinion gear teeth.

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5.  Secure one of the side gears.

6.  Move the pinion gear and measure the backlash at the pinion gear top.

Pinion gear and side gear backlash
0.1 mm {0.004 in} or less
•  If not within the standard, adjust by choosing the proper thrust washer.

Thrust Washer table

Determination mark

Thickness (mm {in})
75
0.75 {0.030}
80
0.80 {0.031}
85
0.85 {0.033}
90
0.90 {0.035}
95
0.95 {0.037}


Side Bearing Assembly Note

Note
•  Do not mix the left and right side bearings.

1.  Press fit the side bearing using the SST, a press, and a steel plate.

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Ring Gear Assembly Note

1.  Install the ring gear to the differential gear case and tighten the bolts in a criss-cross pattern.

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Tightening torque
113—128 N·m {12—13 kgf·m, 84—94 ft·lbf}


Spacer, Adjustment Shim, Differential Gear Case Component Assembly Note

1.  Select the adjustment shim using the following procedure.

(1)  Stack the side bearing outer race and differential gear case component on the surface plate as shown in the figure, and measure the height of the differential gear case component using a vernier caliper and ruler. This is dimension A.
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(2)  Assemble the spacer to the differential carrier.
(3)  Measure the width of the differential carrier section, with the spacer assembled to it, where the differential gear case component will be assembled. This is dimension B.
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(4)  The combined thickness of the left and right adjustment shims is obtained by the following formula. (Reference)
•  C1=B-A+0.01
•  C2=B-A+0.03
(5)  If the combined thickness of the previously assembled adjustment shims is within C1 and C2, use them as they are.
(6)  If the combined thickness of the previously assembled adjustment shims is not within C1 and C2, or if the adjustment shims have to be replaced, select two appropriate adjustment shims from the table below.

Adjustment shim table

Determination mark

Thickness (mm {in})

Determination mark

Thickness (mm {in})
350
3.50 {0.138}
410
4.10 {0.161}
355
3.55 {0.140}
415
4.15 {0.163}
360
3.60 {0.142}
420
4.20 {0.165}
365
3.65 {0.144}
425
4.25 {0.167}
370
3.70 {0.146}
430
4.30 {0.169}
375
3.75 {0.148}
435
4.35 {0.171}
380
3.80 {0.150}
440
4.40 {0.173}
385
3.85 {0.152}
445
4.45 {0.175}
390
3.90 {0.154}
450
4.50 {0.177}
395
3.95 {0.156}
455
4.55 {0.179}
400
4.00 {0.157}
460
4.60 {0.181}
405
4.05 {0.159}
—
—

Note
•  Do not mix the right and left adjustment shims when reusing them.
•  Do not mix the right and left bearing outer races and spacers.

2.  Assemble the differential gear case component, side bearing outer race, adjustment shim (LH), and spacer to the differential carrier.

3.  Assemble the adjustment shim (RH) between the differential carrier and the side bearing race by tapping it using a copper hammer as shown in the figure.

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4.  Perform the ring gear and drive pinion backlash adjustment.

Note
•  Install the SST so that it does not contact the ring gear.
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(1)  Install the SST and dial gauge to the differential carrier using a vise as shown in the figure.
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SST tightening torque
5.0 N·m {51 kgf·cm, 44 in·lbf}
(2)  Secure the drive pinion and measure the backlash from when the ring gear is moved.
Drive pinion and ring gear backlash
Standard: 0.09—0.11 mm {0.0036—0.0043 in}
Minimum: 0.05 mm {0.002 in} or more
Variance: 0.07 mm {0.003 in} or less
Note
•  Measure the backlash at 4 locations around the ring gear. Make sure that 1 of the 4 locations is within the standard, and the minimum value for the 4 locations is 0.05 mm {0.002} in or more and the variance is 0.07 mm {0.003} or less.
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(3)  If the backlash is not within the specification, adjust the gear case component by moving it in the axial direction.
Note
•  Replace the adjustment shim to move the gear case component in the axial direction. At this time, if the adjustment shim on the right side is replaced with one 0.05 mm {0.002}thicker, replace the adjustment shim on the left side with one 0.05 mm {0.002} thinner.

Adjustment shim table

Determination mark

Thickness (mm {in})

Determination mark

Thickness (mm {in})
350
3.50 {0.138}
410
4.10 {0.161}
355
3.55 {0.140}
415
4.15 {0.163}
360
3.60 {0.142}
420
4.20 {0.165}
365
3.65 {0.144}
425
4.25 {0.167}
370
3.70 {0.146}
430
4.30 {0.169}
375
3.75 {0.148}
435
4.35 {0.171}
380
3.80 {0.150}
440
4.40 {0.173}
385
3.85 {0.152}
445
4.45 {0.175}
390
3.90 {0.154}
450
4.50 {0.177}
395
3.95 {0.156}
455
4.55 {0.179}
400
4.00 {0.157}
460
4.60 {0.181}
405
4.05 {0.159}
—
—

(4)  Measure the ring gear preload for the backlash.
Ring gear preload
0.6—1.0 N·m {6.2—10 kgf·cm, 5.4—8.8 in·lbf}
(5)  If the ring gear preload is not within the above specification, adjust the shim thickness by changing the shim.

5.  Perform the drive pinion and ring gear tooth contact inspection using the following procedure.

(1)  Apply tooth marking compound (red lead coating) evenly to both tooth surfaces of the ring gear.
(2)  Rotate the ring gear back and forth several times.
(3)  Inspect the tooth contact pattern in 4 locations around the ring gear and verify that the tooth contact points exhibit the pattern shown in the figure.
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•  If the tooth contact points are normal, wipe off the marking compound.
•  If the tooth contact points are not normal, adjust the pinion height, then adjust the backlash.
―  If the toe and flank contact points appear as shown in the figure after the drive pinion and ring gear tooth contact inspection, replace the spacer with a thinner one to move the drive pinion farther out.
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―  If the heel and face contact points appear as shown in the figure after the drive pinion and ring gear tooth contact inspection, replace the spacer with a thicker one to move the drive pinion closer in.
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Spacer table

Determination mark

Thickness (mm {in})

Determination mark

Thickness (mm {in})
08
3.080 {0.1213}
29
3.290 {0.1295}
09
3.095 {0.1219}
30
3.305 {0.1301}
11
3.110 {0.1224}
32
3.320 {0.1307}
12
3.125 {0.1230}
33
3.335 {0.1313}
14
3.140 {0.1236}
35
3.350 {0.1319}
15
3.155 {0.1242}
36
3.365 {0.1325}
17
3.170 {0.1248}
38
3.380 {0.1331}
18
3.185 {0.1254}
39
3.395 {0.1337}
20
3.200 {0.1260}
41
3.410 {0.1343}
21
3.215 {0.1266}
42
3.425 {0.1348}
23
3.230 {0.1272}
44
3.440 {0.1354}
24
3.245 {0.1278}
45
3.455 {0.1360}
26
3.260 {0.1283}
47
3.470 {0.1366}
27
3.275 {0.1289}
—
—


Rear Cover Assembly Note

1.  Clean the contact surfaces of the differential carrier and rear cover.

Caution
•  Do not apply pressure of 2 t or more with the press. Otherwise, the part may become damaged.
•  For safety purposes, support the differential carrier using a wood block and level the end of the side bearing before performing the procedure.

2.  Apply pressure to the differential gear case component, adjustment shim, and spacer using the SSTs, a press, and a steel plate.

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Caution
•  To prevent silicone sealant from hardening, adhere the rear cover to the differential carrier within 3 min after applying silicone sealant.

3.  Apply silicone sealant (TB1217C) to the positions shown in the figure.

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4.  Install the rear cover to the differential carrier.


Oil Seal (Side Gear) Assembly Note

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

2.  Assemble the oil seal using the SSTs and a hammer.

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