Disassembly and Assembly

Part 1:

Part 2:

DISASSEMBLY
Differential Assembly
1. Drain gear oil, if necessary.
2. Remove carrier cover bolts.





3. Separate the carrier cover from the axle housing using Tool.
Tool number: KV10111100 (J-37228)

CAUTION:
^ Be careful not to damage the mating surface.
^ Do not insert flat-bladed screwdriver, this will damage the mating surface.





4. For proper reinstallation, paint matching marks on one side of the side bearing cap.

CAUTION:
^ For matching mark, use paint. Do not damage side bearing caps and axle housing.
^ Side bearing caps are line-board during manufacture. The matching marks are used to reinstall them in their original positions.





5. Remove side bearing caps.





6. Remove differential case assembly with using suitable tool.





^ Keep side bearing outer races together with inner race. Do not mix them up. Also, keep side bearing adjusting washers together with bearings.





7. Remove side bearing inner race using Tools.
Tool number:
A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)

CAUTION:
^ Engage puller jaws in groove to prevent damage.
^ To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
^ It is not necessary to remove side bearing inner race except if it is replaced.





8. For proper reinstallation, paint matching mark on one differential case assembly

CAUTION: For matching mark, use paint. Do not damage differential case and drive gear.

9. Remove drive gear bolts.
10. Tap drive gear off differential case assembly

CAUTION: Tap evenly all around to keep drive gear from bending.





11. Remove lock pin of pinion mate shaft with punch from drive gear side.





12. Remove pinion mate shaft.





13. Turn pinion mate gear, then remove pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from differential case.

Drive Pinion Assembly
1. Remove differential assembly. Refer to "Differential Assembly".





2. Remove drive pinion lock nut using Tool.
Tool number: KV38108300 (J-44195)





3. Put matching mark on the end of drive pinion. The matching mark should be in line with the matching mark A on companion flange.

CAUTION: For matching mark, use paint. Do not damage companion flange and drive pinion.

NOTE: The matching mark A on the final drive companion flange indicates the maximum vertical runout position. When replacing companion flange, matching mark is not necessary.





4. Remove companion flange using suitable Tool.





5. Remove drive pinion assembly from axle housing using suitable tool.

CAUTION: Do not drop drive pinion assembly.

6. Remove front oil seal.
7. Remove drive pinion front bearing inner race.
8. Remove collapsible spacer.





9. Remove drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool.
Tool number: ST30031000 (J-22912-01)





10. Tap drive pinion front/rear bearing outer races uniformly a brass rod or equivalent.

CAUTION: Be careful not to damage axle housing.

ASSEMBLY
Drive Pinion Assembly





1. Install new front and rear bearing outer races using Tools.
Tool number:
A: ST30611000 (J-25742-1)
B: ST30621000 (J-25742-5)
C: ST30613000 (J-25742-3)

CAUTION:
^ At first, using a hammer, tap bearing outer race until it becomes flat to axle housing.
^ Do not reuse drive pinion front and rear bearing outer race.

2. Select drive pinion height adjusting washer. Refer to "Pinion Gear Height".





3. Install selected drive pinion height adjusting washer to drive pinion. Press new drive pinion rear bearing inner race to it using Tool.
Tool number: ST30901000 (J-26010-01)

CAUTION:
^ Pay attention to the direction of pinion height adjusting washer. (Assemble as shown in the figure.)
^ Do not reuse drive pinion rear bearing inner race.





4. Assemble new collapsible spacer to drive pinion.

CAUTION: Do not reuse collapsible spacer.

5. Apply gear oil to drive pinion rear bearing, and assemble drive pinion into axle housing.
6. Apply gear oil to drive pinion front bearing, and assemble new drive pinion front bearing inner race to drive pinion assembly.

CAUTION: Do not reuse drive pinion front bearing inner race.





7. Press the pinion front bearing inner race onto drive pinion using suitable tool. Press the pinion front bearing inner race as far as the pinion nut can be tightened.





8. Install new front oil seal as shown using Tool.
Tool number: KV38100500 (J-25273)

CAUTION:
^ Do not reuse oil seal.
^ When installing, do not incline oil seal.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.





9. Install companion flange.

NOTE: When reusing drive pinion, align the matching mark of drive pinion with the matching mark A of companion flange, then install companion flange.





10. Apply gear oil to the thread and seat of drive pinion lock nut, and temporarily tighten new drive pinion lock nut to drive pinion.

CAUTION: Do not reuse drive pinion lock nut.

11. Adjust the new drive pinion lock nut tightening torque and pinion bearing preload torque using Tools.
Tool number:
A: KV38108300 (J-44195)
B: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 147 - 323 Nm (15 - 32 kg-m, 109 - 238 ft. lbs.)
Drive pinion bearing preload: 1.1 - 1.4 Nm (0.12 - 0.14 kg-m, 10 - 12 inch lbs.)

CAUTION:
^ Adjust the lower limit of the drive pinion lock nut tightening torque first.
^ If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Do not loosen drive pinion lock nut to adjust the preload torque.
^ After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.

12. Install differential case assembly. Refer to "Differential Assembly".

CAUTION: Do not install carrier cover yet.

13. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion flange runout. Refer to "Drive Gear Runout", "Tooth Contact", "Backlash", "Companion Flange Runout".
Recheck above items. Readjust the above description, if necessary.
14. Check total preload torque. Refer to "Total Preload Torque".
15. Install carrier cover. Refer to "Differential Assembly".

Differential Assembly





1. Install side gear thrust washers with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the side gears.





2. Install side gears and thrust washers into differential case.

CAUTION: Make sure that the circular clip is installed to side gears.

3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and install them into differential case after installing thrust washer to pinion mate gear.





4. Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to "Differential Side Gear Clearance".





6. Drive a lock pin into pinion mate shaft, using suitable tool. Make sure lock pin is flush with differential case.

CAUTION: Do not reuse lock pin.





7. Align the matching mark of differential case with the mark of drive gear, then place drive gear.





8. Apply thread locking sealant into the thread hole of drive gear.
^ Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to "Recommended Chemical Products and Sealants".

CAUTION: Drive gear back and threaded holes shall be cleaned and degreased sufficiently.





9. Install the drive gear bolts, and then tighten to the specified torque. Refer to "COMPONENTS".

CAUTION:
^ Tighten bolts in a crisscross fashion.
^ After tightening the bolt to the specified torque, turn the bolt 31 to 36 more degrees.





10. Press new side bearing inner races to differential case using Tools.
Tool number:
A: ST33230000 (J-25805-01)
B: ST33061000 (J-8107-2)

CAUTION: Do not reuse side bearing inner race.





11. Install differential case assembly with side bearing outer races into axle housing.
12. Measure side bearing preload. If necessary, select the appropriate side bearing adjusting washers. Refer to "Side Bearing Preload".





13. Insert selected left and right side bearing adjusting washers in place between side bearings and axle housing using Tool.
Tool number: KV38100600 (J-25267)





14. Align matching mark on side bearing cap with that on axle housing.
15. Install side bearing caps and tighten side bearing cap bolts to the specified torque. Refer to "COMPONENTS".
16. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque. Refer to "Drive Gear Runout", "Tooth Contact", "Backlash", "Total Preload Torque".
Recheck above items. Readjust the above description, if necessary





17. Apply sealant to mating surface of carrier cover.
^ Use Genuine Silicone RTV or equivalent. Refer to "Recommended Chemical Products and Sealants".

CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating surfaces.

18. Install carrier cover on axle housing and tighten bolts with the specified torque. Refer to "COMPONENTS".