Front

DISASSEMBLY
1. CHECK RUNOUT OF COMPANION FLANGE





Using a dial indicator, measure the vertical and lateral runout of the companion flange.

Maximum runout: 0.10 mm (0.0039 inch)

If the runout is greater than the maximum, replace the companion flange.
2. CHECK RING GEAR BACKLASH





Using SST and a dial indicator, measure the ring gear backlash.
SST 09564-32011

Backlash: 0.10 - 0.18 mm (0.0039 - 0.0071 inch)

If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.
3. MEASURE DRIVE PINION PRELOAD





Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.

Preload (at starting): 0.6 - 1.0 Nm (6 - 10 kgf.cm, 5.2 - 8.7 inch lbs.)

4. CHECK TOTAL PRELOAD
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 0.4 - 0.6 Nm (4 - 6 kgf.cm, 3.5 - 5.2 inch lbs.)

If necessary, disassemble and inspect the differential.
5. w/ A.D.D.:
REMOVE A.D.D. ACTUATOR
a. Remove the 4 bolts.





b. Using a hammer handle, remove the actuator.
6. w/ A.D.D.:
REMOVE DIFFERENTIAL TUBE





a. Remove the 4 torx bolts.
Torx socket E14 (Part No.09044-00010 or locally manufactured tool)
b. Using a plastic hammer, remove the differential tube.
c. Remove the sleeve.
d. Remove the O-ring from the differential tube.
7. w/o A.D.D.:
REMOVE DIFFERENTIAL TUBE
a. Remove the 4 bolts.
b. Using a plastic hammer, remove the differential tube.
8. w/ A.D.D.:
REMOVE CLUTCH CASE
a. Remove the 2 torx bolts.
Torx socket E14 (Part No.09044-00010 or locally manufactured tool)
b. Using a plastic hammer, remove the clutch case.
9. REMOVE SIDE OIL SEAL





Using SST, remove the side oil seal.
SST 09308-00010
10. w/ A.D.D.:
REMOVE INTERMEDIATE SHAFT NO.1





Using SST, remove the intermediate shaft No. 1.
SST 09350-20015 (09369-20040), 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04010, 09957-04010, 09958-04010)
11. REMOVE COMPANION FLANGE
a. Using a chisel and hammer, unstake the nut.





b. Using SST to hold the flange, remove the nut.
SST: 09330-00021





c. Using SST, remove the companion flange.
SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
12. REMOVE OIL SEAL AND OIL SLINGER





a. Using SST, remove the oil seal.
SST 09308-10010
b. Remove the oil slinger.
13. REMOVE REAR BEARING AND BEARING SPACER





a. Using SST, remove the rear bearing from the drive pinion.
SST 09556-22010
b. Remove the bearing spacer.
14. REMOVE SIDE BEARING RETAINER
Remove the 10 bolts and tap out the retainer with a plastic hammer.
15. REMOVE DIFFERENTIAL CASE ASSEMBLY
16. REMOVE DRIVE PINION FROM DIFFERENTIAL CARRIER
17. REMOVE DRIVE PINION FRONT BEARING





Using SST and a press, remove the bearing and washer from the drive pinion.
SST 09950-00020

HINT: If the drive pinion or ring gear are damaged, replace them as a set.

18. REMOVE DRIVE PINION BEARING OUTER RACES





a. Using a brass bar and hammer, remove the front bearing outer race.





b. Using SST, remove the rear bearing outer race.
SST 09502-12010, 09612-65014 (09612-01020, 09612-01050)
19. REMOVE SIDE BEARING OUTER RACES

HINT
^ Measure the plate washer and note the thickness.
^ Tag the bearing outer races to show the location for reassembly.





a. Using SST and a press, remove the outer race and plate washer from the bearing retainer.
SST 09950-60010 (09951-00540), 09550-70010 (09951-07150)





b. Using SST and a press, remove the outer race and plate washer from the differential carrier.
SST 09950-60010 (09951-00650), 09950-70010 (09951-07150)
20. REMOVE RING GEAR





a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver, unstake the 5 lock plates.
c. Remove the 10 bolts and 5 lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
21. REMOVE SIDE BEARINGS





Using SST, remove the 2 side bearings from the differential case.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04060, 09957-04010, 09958-04010), 09950-60010 (09951-00480)

HINT: Fix the claws of SST to the notch in the differential case.

22. DISASSEMBLE DIFFERENTIAL CASE ASSEMBLY





a. Using a pin punch and hammer, remove the straight pin.
b. Remove these parts:
Pinion shaft
- 2 pinion gears
- 2 pinion gear thrust washers
- 2 side gears
- 2 side gear thrust washers
23. w/ A.D.D.:
REMOVE BEARINGS





Using a brass bar and hammer, remove the 2 bearings.

REPLACEMENT
1. REPLACE COMPANION FLANGE DUST DEFLECTOR, IF NECESSARY





a. Using SST and a press, remove the dust deflector.
SST 09950-00020





b. Using SST and a press, install a new dust deflector.
SST 09636-20010
2. REPLACE INTERMEDIATE SHAFT NO.2, IF NECESSARY
a. w/ A.D.D.:





Remove the clutch hub.
1) Using a snap ring expander, remove the snap ring.
2) Remove the clutch hub from the intermediate shaft No.2.

b. Remove the oil seal.





Using SST, remove the oil seal from the differential tube.
SST 09308-00010
c. Remove the intermediate shaft No.2
1) Using needle nose pliers, remove the snap ring.
2) Remove the shaft from the differential tube.
d. Remove the intermediate shaft No.2 bearing.
1) Using a snap ring expander, remove the snap ring.





2) Using SST, a brass bar and press, remove the bearing.
SST 09950-00020
e. Install a new intermediate shaft No.2 bearing.





1) Using SST and a press, install a new bearing.
SST 09309-37010
2) Using a snap ring expander, install the snap ring.
f. Install the intermediate shaft No.2
1) Install the shaft into the differential tube.
2) Using needle nose pliers, install the snap ring.
g. Install a new oil seal.





1) Using SST, install a new oil seal.
SST 09223-15020

Oil seal drive in depth: 5.5 mm (0.217 inch)

2) Coat the oil seal lip with MP grease.
h. w/ A.D.D.:
Install the clutch hub.





1) Install the clutch hub to the intermediate shaft No.2.
2) Using snap ring pliers, install the snap ring.
3. REPLACE A.D.D. ACTUATOR, IF NECESSARY
a. Remove the A.D.D. switch.
b. Remove the sleeve fork pin.
1) Using a hexagon wrench, remove the screw plug.





2) Using a pin punch and hammer, remove the pin through the hole of clutch case cover.
c. Separate A.D.D. actuator from clutch case cover and remove the sleeve fork.
1) Using a hexagon wrench, remove the screw plug.
2) Remove the spring seat, spring and steel ball.
3) Remove the 2 bolts and actuator from the clutch case cover.
4) Separate the actuator from the clutch case cover and remove the sleeve fork.
5) Remove the O-ring from the actuator.





d. Install the sleeve fork and A.D.D. actuator into the clutch case cover.
1) Install a new O-ring to the actuator.
2) Coat the O-ring with MP grease.
3) Place the sleeve fork and install the actuator to the clutch case cover.
4) Torque the 2 bolts.

Torque: 21 Nm (210 kgf.cm, 15 ft. lbs.)

5) Install the steel ball, spring and spring seat.
6) Coat the threads of screw plug with FIPG.

FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

7) Using a hexagon wrench, install the screw plug.

Torque: 13 Nm (130 kgf.cm, 9 ft. lbs.)

e. Install the sleeve fork pin.
1) Using a pin punch and hammer, install the pin through the hole of clutch case cover.
2) Coat the threads of screw plug with FIPG.

FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

3) Using a hexagon wrench, install the screw plug.

Torque: 20 Nm (200 kgf.cm, 14 ft. lbs.)

f. Install the A.D.D. switch.
Install a new gasket and A.D.D. switch.

Torque: 40 Nm (410 kgf.cm, 30 ft. lbs.)

REASSEMBLY
1. w/ A.D.D.:
INSTALL NEW BEARINGS





Using SST and a press, install 2 new bearings.
SST 09950-60010 (09951-00380)

Bearing press in depth: 0.3 ± 0.3 mm (0.012 ± 0.012 inch)

2. ASSEMBLE DIFFERENTIAL CASE





a. Install the 2 proper thrust washers on the 2 side gears.





Washer thickness

HINT: Using the table, select 2 thrust washers which will ensure that the backlash is within the specifications.

b. Install the 2 side gears, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft in the differential case.

HINT: Align the holes of the differential case and pinion shaft.





c. Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the differential case.

Backlash: 0 - 0.20 mm (0 - 0.0079 inch)

If the backlash is not within the specification, install 2 side gear thrust washers with different thicknesses.
3. INSTALL STRAIGHT PIN AND STAKE DIFFERENTIAL CASE





a. Using a pin punch and hammer, install the straight pin through the differential case and hole of the pinion shaft.
b. Stake the differential case.
4. INSTALL RING GEAR ON DIFFERENTIAL CASE
a. Clean the contact surfaces of the differential case and ring gear.





b. Heat the ring gear to about 100°C (212°F) in boiling water.
c. Carefully remove the ring gear from the boiling water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

HINT: Align the matchmarks on the ring gear and differential case.

e. Temporarily install 5 new lock plates and 10 bolts so that the bolt holes in the ring gear and differential case are not misaligned.
f. After the ring gear has cooled sufficiently, torque the ring gear set bolts.

Torque: 97 Nm (985 kgf.cm, 71 ft. lbs.)





g. Using a drift punch and hammer, stake the 5 lock plates.

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

5. INSTALL SIDE BEARINGS





Using SST and a press, install the 2 bearings into the differential case.
SST 09226-10010
6. INSTALL SIDE BEARING OUTER RACES

HINT: When replacing the 2 side bearings, fit the 2 thinnest washers to each bearing and when reusing the bearings, fit the washers with the same thickness as removed.

a. Install a new plate washer to the side bearing retainer.





b. Using SST and a press, install the bearing outer race.
SST 09950-60020 (09951-00790), 09950-70010 (09951-07150)
c. Install a new plate washer to the differential carrier.





d. Using SST and a press, install the bearing outer race.
SST 09950-60020 (09951-00790), 09950-70010 (09951-07150)
7. INSTALL DRIVE PINION FRONT AND REAR BEARING OUTER RACES





Using SST, install the 2 outer races.
SST 09570-22011
8. INSTALL DRIVE PINION FRONT BEARING
a. Install the washer on the drive pinion.

HINT: First fit a washer with the same thickness with the removed washer, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.





b. Using SST and a press, install the front bearing onto the drive pinion.
SST 09506-30012

9. TEMPORARILY ADJUST DRIVE PINION PRELOAD
a. Install the drive pinion and oil slinger.

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





b. Using SST, install the rear bearing, oil slinger and companion flange.
SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
c. Coat the threads of the nut with hypoid gear oil.





d. Adjust the drive pinion preload by tightening the companion flange nut.
Using SST to hold the flange, tighten the nut.
SST 09330-00021

NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.





e. Using a torque wrench, measure the preload.

Preload (at starting)
New bearing: 1.2 - 1.9 Nm (12 - 19 kgf.cm, 10.4 - 16.5 inch lbs.)
Reused bearing: 0.6 - 1.0 Nm (6 - 10 kgf.cm, 5.2 - 8.7 in.-lbs.)

10. INSTALL DIFFERENTIAL CASE IN DIFFERENTIAL CARRIER
11. ADJUST RING GEAR BACKLASH
a. Install the side bearing retainer with the 10 bolts.

Torque: 69 Nm (700 kgf.cm, 51 ft. lbs.)





b. Using SST and a dial indicator, measure the ring gear backlash.
SST 09564-32011

Backlash: 0.10 - 0.18 mm (0.0039 - 0.0070 inch)

c. If it is not within the specification, adjust it by either in creasing or decreasing the washers on both sides by an equal amount.

HINT: There should be no clearance between the plate washer and case. Make sure that there is ring gear backlash.





Washer thickness

12. MEASURE TOTAL PRELOAD





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 0.4 - 0.6 Nm (4 - 6 kgf.cm, 3.5 - 5.2 inch lbs.)

13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Remove the side bearing retainer and differential case.
b. Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead.
c. Install the differential case and side bearing retainer.

Torque: 69 Nm (700 kgf.cm, 51 ft. lbs.)

d. Hold the companion flange firmly and rotate the ring gear in both directions.
e. Remove the side bearing retainer and differential case.





f. Inspect the tooth contact pattern.





If the teeth are not contacting properly, use the following chart to select a proper washer for correction.





Washer Thickness

14. REMOVE COMPANION FLANGE AND OIL SLINGER
15. REMOVE REAR BEARING
16. INSTALL NEW BEARING SPACER, REAR BEARING AND OIL SLINGER
a. Install a new bearing spacer and place the rear bearing and oil slinger.





b. Using SST and the companion flange, install the rear bearing, then remove the companion flange.
SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
17. INSTALL OIL SEAL
a. Coat a new oil seal lip with MP grease.





b. Using SST and a hammer, install the oil seal.
SST 09554-22010

Oil seal drive in depth: 4.5 mm (0.177 inch)

18. INSTALL COMPANION FLANGE
a. Place the companion flange on the drive pinion.
b. Coat the threads of a new nut with hypoid gear oil.





c. Using SST to hold the flange, torque the nut.
SST 09330-00021

Torque: 108 Nm (1,100 kgf.cm, 80 ft. lbs.)

19. ADJUST DRIVE PINION PRELOAD





Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

Preload (at starting):
New bearing: 1.2 - 1.9 Nm (12 -19 kgf.cm, 10.4 - 16.5 inch lbs.)
Reused bearing: 0.6 - 1.0 Nm (6 - 10 kgf.cm, 5.2 - 8.7 inch lbs.)

If the preload is greater than the specification, replace the bearing spacer.
If the preload is less than the specification, retighten the nut 13 Nm (130 kgf.cm, 9 ft. lbs.) a little at a time until the specified pre-load is reached.

Torque: 223 Nm (2,275 kgf.cm, 165 ft. lbs.) or less

If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure.
Do not back off the nut to reduce the preload.
20. INSTALL DIFFERENTIAL CASE
21. INSTALL SIDE BEARING RETAINER





a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and side bearing retainer.
b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.
c. Apply FIPG to the side bearing retainer, as shown.

FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

HINT: Install the side bearing retainer within 10 minutes after applying FIPG.

d. Install the side bearing retainer with the 10 bolts.

Torque: 69 Nm (700 kgf.cm, 51 ft. lbs.)

22. CHECK TOTAL PRELOAD
23. RECHECK RING GEAR BACKLASH
24. RECHECK TEETH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See step 13)
25. CHECK RUNOUT OF COMPANION FLANGE
26. STAKE DRIVE PINION NUT
27. INSTALL SIDE OIL SEAL





a. Using SST and a plastic hammer, install a new oil seal until its surface is flush with the differential carrier end.
SST 09608-32010
b. Coat the oil seal lip with MP grease.
28. w/ A.D.D.:
INSTALL INTERMEDIATE SHAFT No 1.
a. Install a new snap ring to the intermediate shaft No. 1.





b. Using a plastic hammer, install the intermediate shaft No. 1 to the differential case.
c. Check that there is 2 - 3 mm (0.08 - 0.12 inch) of play in axial direction.
d. Check that the intermediate shaft No. 1 will not come out by trying to pull it completely out by hand.
29. w/ A.D.D.:
INSTALL CLUTCH CASE TO DIFFERENTIAL TUBE
a. Install a new O-ring to the tube.





b. Coat the O-ring with MP grease.
c. Install the clutch case to the tube.
d. Torque the 2 torx bolts.
Torx socket E14 (Part No.09044-00010 or locally manufactured tool)

Torque: 78 Nm (800 kgf.cm, 58 ft. lbs.)

30. w/ A.D.D.:
INSTALL CLUTCH SLEEVE
31. INSTALL DIFFERENTIAL TUBE TO DIFFERENTIAL





a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential and clutch case.
b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.
c. Apply FIPG to the differential, as shown.

FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

HINT: Install the differential tube within 10 minutes after applying FIPG.

d. Install the differential tube to the differential.





e. Clean the threads of the 4 bolts (w/o A.D.D.) or 2 torx bolts (w/ A.D.D.) and retainer bolt holes with toluene or trichloroethylene.
f. Apply adhesive to 2 or 3 threads of the bolts end.

Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent

g. Torque the 4 bolts (w/o A.D.D.) or 4 torx bolts (w/ A.D.D.). Torx socket E14 (Part No. 09044-00010 or locally manufactured tool).

Torque:
w/o A.D.D.: 105 Nm (1,070 kgf.cm, 77 ft. lbs.)
w/ A.D.D.: 78 Nm (800 kgf.cm, 58 ft. lbs.)

32. w/ A.D.D.:
INSTALL A.D.D. ACTUATOR





a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the actuator and clutch case.
b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.
c. Apply FIPG to the clutch case, as shown.

FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

HINT: Install the actuator within 10 minutes after applying FIPG.

d. Torque the 4 bolts.

Torque: 21 Nm (210 kgf.cm, 15 ft. lbs.)