REAR DIFFERENTIAL DISASSEMBLY/ASSEMBLY

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Disassembly

Warning

• The engine stand is equipped with a self-lock mechanism. However, if the rear differential is tilted, the self-lock mechanism could become inoperative. This could cause the rear differential to rotate accidentally, resulting in injury. Therefore, make sure that the rear differential is not tilted when it is on the engine stand. When turning the rear differential, grasp the rotation handle firmly.

1. Install the SSTs to the engine stand.

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2. Remove the needle bearing and the oil seal using the SSTs.

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3. Place an alignment mark on the bearing cap and the carrier, and remove the bearing cap.

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4. Remove the differential case using the SSTs.

Caution

• Overspreading can damage the axle housing.

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(1) Spread the axle housing.

(2) Remove the differential case and tag the bearing caps to indicate which side of the carrier they were removed from.

5. Remove the SSTs.

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6. Remove the locknut using the SSTs.

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7. Remove the drive pinion, collapsible spacer and drive pinion bearings.

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(1) Remove the drive pinion, collapsible spacer, and drive pinion bearings.

(2) Remove the outer drive pinion bearing.

(3) Discard the collapsible spacer.

8. Remove the drive outer and inner drive pinion bearing cups using the SSTs.

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Caution

• Be careful not to damage the axle housing when removing the inner drive pinion bearing cup.

• Install a new oil baffle between the inner drive pinion bearing cup and the axle housing bore at the time of assembly.

9. Remove the oil baffle.

10. Remove the side bearing inner race from the gear case using the SST and a press.

Note

• Put left and right identification tags on the side bearings.

• Discard any damaged shims.

(1) Left side

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(2) Right side

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11. Remove the ring gear.

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Warning

• Gear teeth have sharp edges. Be careful when handling the drive pinion. Failure to follow these instructions may cause personal injury.

(1) Remove and discard the bolts.

(2) Remove the ring gear.

12. Remove the differential pinion shaft.

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(1) Remove the differential pinion shaft lock pin.

(2) Remove the differential pinion shaft.

13. Remove the two pinion gears, two side gears, and four thrust washers.

Caution

• Make sure to note the location of the pinion gears, the side gears, and the thrust washers to assemble in the same locations.

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(1) Rotate the pinion gears and the pinion gear thrust washers to the opening and remove.

(2) Remove the side gears and the side gear thrust washers.

14. Remove the drive pinion bearing and the drive pinion position shim using the SSTs.

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Assembly

1. Install a new oil baffle, and the inner and outer drive pinion bearing cups using the SSTs.

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Caution

• When assembly, install a new oil baffle between the inner drive pinion bearing cup and the axle housing bore.

(1) Apply dry type lubricant to the drive pinion bearing cup bore.

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

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Note

• Use the assembled spacer.

• Assemble the spacer with chamfered side facing the SST.

3. Insert the set assembled in Step 2 from the rear side of the differential carrier.

4. Assemble the bearing inner race (front), the SST (49 8531 567), the companion flange, the washer, and the locknut from the front side of the differential carrier.

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

6. Place the SST (49 0305 555) on the SST (49 8531 565).

7. Place the SST on the surface plate and set the dial gauge to zero.

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8. Set the SST as shown in the figure.

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9. Place the measuring probe of the dial gauge at the point where the side bearing is installed in the carrier and measure at the lowest position. Measure at both side (left and right).

10. Add the two (left and right) values obtained by the measurements taken in Step 9 and divide the total by two. Add 0.3435 to the value, and subtract the value written on the drive pinion. This is the pinion height adjustment value. (If the value is plus, abate. If the value is minus, add.)

Note

• When the values obtained by the measurements taken in Steps 9 and 10 are - 0.2 mm {0.008 in} and - 0.3 mm {0.011 in}, and the number on the end of the drive pinion is + 0.02, the formula is: (((- 0.2) + (- 0.3)) / 2) - 0.02 + 0.3435 = 0.0735. Therefore, assemble a spacer 0.0735 mm{0.003 in} thicker than the currently assembled one. Choose and install the spacer closest in thickness.

11. Install the drive pinion adjustment shim and the bearing using the SSTs.

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Caution

• The same pinion bearings and drive pinion bearing cups used in the drive pinion adjustment shim selection procedure must be used in the final axle assembly.

(1) Position the drive pinion adjustment shim.

(2) Position the drive pinion bearing.

(3) Position the SSTs.

(4) Install the drive pinion bearing securely to the drive pinion using a press.

12. Install a new collapsible spacer.

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Caution

• Do not reuse the old collapsible spacer.

13. Install the drive pinion and a new drive pinion nut using the SST.

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(1) Rotate the drive pinion counterclockwise until all end play is removed then tighten the drive pinion nut.

14. Inspect the drive pinion rotational torque and adjust if necessary.

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Caution

• If the rotational torque is less than the specification, tighten the drive pinion nut in small increments until it is within the specification. Do not tighten the drive pinion nut with a tightening torque of 628 N·m or more. If the rotation torque is higher than the specification, the collapsible spacer is compressed too far and a new collapsible spacer must be installed.

Note

• When tightening the drive pinion nut to remove initial end play, torque may exceed the maximum specification. Once end play is removed and the collapsible spacer starts collapsing, the torque should drop into the specified range.

• Rotate the drive pinion 10 revolutions before the measurement.

15. Install the differential case to the axle housing using the SST.

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Note

• The differential case should move freely in the axle housing.

16. After assembling the differential case away from the drive pinion, measure and record the differential case total end play while pushing the differential case toward the drive pinion.

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Note

• Repeat this step until a same reading is obtained twice.

17. Remove the differential case and the SSTs.

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Note

• Take note which side each SST was removed from so they can be installed on the same side of differential case for the next measurement with the ring gear installed.

18. Install the two pinion gears, two side gears and four thrust washers.

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Caution

• If reusing the pinion gears, the side gears, or the thrust washers, install in the same locations that they were removed.

(1) Position the side gears and the side gear thrust washers.

(2) Rotate the pinion gears and the pinion gear thrust washers to the differential pinion shaft hole in the differential case.

(3) Apply SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting the specification WSL-M2C192-A to the pinion gears, the side gears, and the thrust washers.

19. Install the differential pinion shaft.

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(1) Install the differential pinion shaft.

(2) Install the differential pinion shaft lock pin.

20. Install the ring gear.

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(1) Position the ring gear.

(2) Install new ring gear bolts in a criss-cross pattern and evenly pattern.

21. Install the differential case to the axle housing using the SSTs.

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(1) Install the SSTs on the same ends of the differential case as they were previously installed.

22. After assembling the differential case away from the drive pinion, measure and record the differential case total end play while pushing the differential case toward the drive pinion.

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Note

• Repeat this step until a same reading is obtained twice.

23. Remove the differential case and the SSTs.

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24. Calculate for the differential case bearing shims as follows:

Differential case shim selection

Value

Step 1

Total differential case end play (without ring gear installed)

Step 2

Total differential case end play (with ring gear installed)

Step 3

Step 1 - Step 2

Step 4

Total shims necessary for the ring gear side of differential case (Step 2 + 0.076 mm {0.003 in})

Step 5

Total shims necessary for the opposite side of the ring gear of differential case (Step 3 + 0.25 mm) {0.01 in}

Example

Differential case shim selection		Value
Step 1	Total differential case end play (without ring gear installed)	1.066 mm {0.042 in}
Step 2	Total differential case end play (with ring gear installed)	0.660 mm {0.026 in}
Step 3	Step 1 - Step 2	0.406 mm {0.016 in}
Step 4	Total shims necessary for the ring gear side of differential case (Step 2 + 0.076 mm {0.003 in})	0.736 mm {0.029 in}
Step 5	Total shims necessary for the opposite side of the ring gear of differential case (Step 3 + 0.25 mm {0.01 in})	0.656 mm {0.026 in}

25. Measure the width of the SSTs used on the ends of the differential case and select differential case bearing shims if necessary.

Note

• If the SSTs do not measure 18.136 mm {0.714 in}±0.025 mm {0.001 in}, the numbers in Step 1 will be overstated by the difference from 18.136 mm {0.714 in}measured on each SST. The number in Step 2 will be overstated by the difference measured on the SST on the other side. Adjustments to the shim will have to be made in order to prevent bearing pre-loads from becoming excessive.

26. Install the differential case bearings and correct shims using the SSTs.

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27. Install the differential case using the SSTs.

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(1) Spread the axle housing.

(2) Install the differential case.

28. Remove the SSTs.

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29. Install the bearing caps.

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(1) Position the bearing caps in the position they were removed.

(2) Install the bolts.

30. Measure and adjust the ring gear backlash if necessary.

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Note

• The ring gear backlash should be measured at three equally spaced points on the ring gear. If there is high backlash, the ring gear must be moved closer to the drive pinion by moving shims to the ring gear side from the opposite side. If there is low backlash, the ring gear must be moved away from the drive pinion by moving shims from the ring gear side to the opposite side.

31. Position the axle component with the drive pinion stem facing upward.

32. Measure and record the total turning torque to rotate the drive pinion and adjust if necessary.

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Note

• The total turning torque should be the drive pinion rotational torque +0.68—1.13 N·m {7.0—11.5 kgf·cm, 7—10 in·lbf}. If the total turning torque is too high, subtract an equal amount of shims from each side of the differential case. If the total turning torque is too low, add an equal amount of shims to both sides of the differential case.

33. Install the needle bearings using the SSTs.

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Caution

• Lubricate the needle bearings with multi-purpose grease prior to installation.

34. Install the oil seals using the SSTs.

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