Part 2

REAR DIFFERENTIAL CARRIER ASSEMBLY(continued)

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

REASSEMBLY

1. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
(a) Using SST, a press and a steel plate, install the dust deflector.
SST 09636-20010

NOTICE: Be careful not to damage the dust deflector.

2. INSTALL DIFFERENTIAL CASE ASSEMBLY
(a) Install the rear differential side gear thrust washer onto the rear differential side gear.
(b) Install the 4 rear differential pinion thrust washers and rear differential pinion gears onto the rear differential spider.
(c) Fix the differential case RH.

(d) Install the rear differential side gear and rear differential spider onto the differential case RH.

(e) Using a dial indicator, measure the differential case RH side backlash while holding the pinion toward the case.
Backlash: 0.05 to 0.20 mm (0.002 to 0.008 in.)
(f) Remove the rear differential spider from the differential case RH.

(g) Install the rear differential side gear and rear differential spider onto the differential case LH.
(h) Using a dial indicator, measure the differential case LH side backlash while holding the pinion toward the case.

HINT: Measure at all 4 locations.

Backlash: 0.05 to 0.20 mm (0.002 to 0.008 in.)
If the backlash is not within the specification, install 2 side gear thrust washers of a different thickness.

Thrust washer thickness:

(i) Install the differential side gear thrust washer to the RH case.
(j) Install the differential pinion gears and differential spider to the RH case.
(k) Install the differential side gear and differential side gear thrust washer to the RH case.

(l) Align the matchmarks and assemble the RH and LH cases.
(m) Using a plastic hammer, install the RH and LH case.
(n) Install the 8 bolts.
Torque: 47 Nm (480 kgf/cm, 35 ft. lbs.)

3. INSTALL REAR DIFFERENTIAL CASE BEARING
(a) Using SST and a press, install the 2 differential case bearings onto the differential case assembly.
SST 09223-15020, 09950-60010 (09951-00480, 09951-00550), 09950-60020 (09951-00730)

4. INSTALL DIFFERENTIAL RING GEAR
(a) Clean the contact surfaces of the differential case assembly and ring gear.
(b) Heat the ring gear to approximately 100°C (212°F) in boiling water.
(c) Carefully take the ring gear out of the boiling water.
(d) After the moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case.

(e) Align the matchmarks on the ring gear and differential case assembly.
(f) Temporarily install 5 new lock plates and 10 set bolts.
(g) After the ring gear cools down sufficiently, torque the 8 bolts uniformly at a time.
Torque: 97 Nm (985 kgf/cm, 71 ft. lbs.)

HINT: Tighten the bolts in diagonal order little by little in several steps.

(h) Using a chisel and a hammer, stake the 5 lock plates.

HINT: Stake one claw so that it is flush with the flat surface of the bolt. For the claw in contacting with the protruding portion of the bolt, stake only the half on the tightening side.

5. INSPECT DIFFERENTIAL RING GEAR RUNOUT
(a) Install the differential case onto the carrier, and install the 2 adjusting nuts so that there is no play in the bearing.
(b) Install the 2 bearing caps with the 4 bolts.
Torque: 85 Nm (867 kgf/cm, 63 ft. lbs.)
(c) Install the 2 adjusting nut locks with the 2 bolts.
Torque: 13 Nm (130 kgf/cm, 9 ft. lbs.)
(d) Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 in.)
If it is not within the specification, replace the ring gear.
(e) Remove the 2 bolts and adjusting nut locks.
(f) Remove the 2 bearing caps, 2 adjusting nuts and differential case assembly.

6. INSTALL FRONT BEARING OUTER RACE
(a) Using a brass bar and a hammer, install a new oil storage ring.
(b) Using SST and a hammer, install the front bearing outer race to the differential carrier assembly.
SST 09316-60011 (09316-00011, 09316-00021)

7. INSTALL REAR BEARING OUTER RACE
(a) Using SST and a press, install the rear bearing outer race to the differential carrier case.
SST 09316-60011 (09316-00011, 09316-00051)

8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Install the plate washer onto the drive pinion.
(b) Using SST and a press, install the rear bearing onto the drive pinion.
SST 09506-30012

9. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Install the drive pinion, front bearing and oil slinger.

HINT: Assemble the spacer and oil seal after adjusting the gear contact pattern.

(b) Using SST, install the drive pinion companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)
(c) Coat the threads of the nut with hypoid gear oil LSD.

(d) Using SST to hold the drive pinion companion flange, tighten the nut.
Torque: 215 Nm (2,190 kgf/cm, 159 ft. lbs.)
SST 09330-00021

NOTICE:
^ As there is no spacer, tighten a little at a time, being careful not to overtighten it.
^ Apply hypoid gear oil LSD to the nut.

(e) Using a torque wrench, measure the preload.

Preload (at starting):

HINT: Measure the total preload after first turning the bearing clockwise and counterclockwise several times to make the bearing smooth.

10. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Place the 2 bearing outer races on their corresponding bearings.
(b) Install the differential case assembly in the differential carrier assembly.

HINT:
^ Make sure the right and left races are not interchanged.
^ Make sure that there is a backlash between the ring rear and drive pinion.

11. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT
(a) Install the rear differential bearing adjusting nuts into the carrier, making sure the nuts are threaded properly.

12. ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION
(a) Align the matchmarks on the bearing cap and differential carrier assembly.
(b) Install the 2 bearing caps with the 4 bolts.
Torque: 85 Nm (867 kgf/cm, 63 ft. lbs.)

HINT: If the bearing cap does not fit tightly on the differential carrier assembly, the adjusting nuts are not threaded properly. Reinstall the adjusting nuts if necessary.

(c) Tighten the 4 bearing cap bolts to the specified torque, then loosen them to the point where the adjusting nuts can be turned by SST.
SST 09504-00011

(d) Using the SST, tighten the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008 in.).
SST 09504-00011

(e) While turning the ring gear, use the SST to fully tighten the adjusting nut on the drive pinion side.
After the bearings have settled, loosen the adjusting nut on the drive pinion side.
(f) Using SST, torque the adjusting nut 1 to 1.5 notches from the 0 preload position.

(g) Using a dial indicator, adjust the ring gear backlash until it is within the specification.
Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.)
SST 09504-00011

HINT: The backlash is adjusted by turning the left and right adjusting nuts for an equal amounts. For example, loosen the nut on the right side by one notch.

(h) Torque the bearing cap bolts.
Torque: 85 Nm (867 kgf/cm, 63 ft. lbs.)

13. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus 0.39 to 0.59 Nm (4.0 to 6.0 kgf/cm, 3.5 to 5.2 in. lbs.)
If necessary, disassemble and inspect the differential.

14. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.
(b) Hold the companion flange firmly and rotate the ring gear in both directions.

If the teeth are not engaged properly, use the following chart to select an appropriate washer for correction.

Plate Washer thickness:

15. REMOVE REAR DRIVE PINION NUT
(a) Using SST to hold the drive pinion companion flange, remove the nut.
SST 09330-00021
16. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
(a) Using SST, remove the drive pinion companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)
17. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST, remove the drive pinion tapered roller bearing from the drive pinion.
SST 09556-22010
19. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new bearing spacer onto the drive pinion.
20. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Install the drive pinion, rear drive pinion taper roller bearing and rear differential drive oil slinger.
21. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST and a hammer, install a new carrier oil seal.
SST 09554-30011
Oil seal drive in depth: 0.55 to 1.45 mm (0.021 to 0.057 in.)
(b) Coat the oil seal lip with the MP grease.

23. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
(a) Using SST, install the drive pinion companion flange onto the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030), 09330-00021
(b) Coat the threads of a new nut with hypoid gear oil LSD.

24. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

Preload (at starting):

If the preload is greater than the specification, replace the bearing spacer.
If the preload is less than the specification, retighten the nut to 13 Nm (130 kgf/cm, 9 ft. lbs.) of torque at a time until the specified preload is reached.
Torque: 370 Nm (3,773 kgf/cm, 27 ft. lbs.) or less
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure. Do not loosen the pinion nut to reduce the preload.

25. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus 0.39 to 0.59 Nm (4.0 to 6.0 kgf/cm, 3.5 to 5.2 in. lbs.)
If necessary, disassemble and inspect the differential.

26. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Using a dial indicator, check the backlash of the ring gear.
Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.)
If the backlash is not within the specification, adjust or repair the side bearing preload as necessary.

27. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
(a) Using a dial indicator, measure the runout of the drive pinion companion flange vertically and horizontally.
Maximum runout:
Vertical runout: 0.10 mm (0.0039 in.)
Lateral runout: 0.10 mm (0.0039 in.)
If the runouts are not within the specifications, replace the companion flange.

28. INSTALL REAR DRIVE PINION NUT
(a) Using a chisel and hammer, stake the drive pinion nut.
(b) 2WD drive type: Using a "Torx" socket (E10), install the 4 stud bolts.
Torque: 10 Nm (101 kgf/cm, 7.3 ft. lbs.)

29. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK
(a) Install 2 new rear differential bearing adjusting locks onto the bearing caps.
Torque: 13 Nm (130 kgf/cm, 9 ft. lbs.)
(b) After tightening the 2 bolts, bend the nut locks.