With Open Differential

DISASSEMBLY
1. SET DIFFERENTIAL CARRIER TO OVERHAUL STAND, ETC.





2. 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 then the maximum, replace the companion flange.





3. CHECK RING GEAR RUNOUT
Using a dial indicator, while holding the drive pinion flange, measure the ring gear runout.

Maximum runout: 0.05 mm (0.0020 inch)

If the runout is greater than the maximum, replace the ring gear.





4. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)

HINT: Perform the measurements at 3 or more positions around the circumference of the ring gear. If the backlash is not within the specified value, adjust the side bearing preload or repair as necessary.





5. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the drive pinion preload using the backlash of the drive pinion and ring gear.

Preload (at starting): 0.64 - 0.92 Nm (6.5 - 9.4 kgf-cm, 5.7 - 8.1 inch lbs.)

6. CHECK TOTAL PRELOAD
Using a torque wrench, measure the total preload with the teeth of the drive pinion and ring gear in contact.

Total preload (at starting):
Drive pinion preload plus: 0.38 - 0.63 Nm (3.9 - 6.5 kgf-cm, 3.3 - 5.6 inch lbs.)

If necessary, disassemble and inspect the differential.
7. CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
8. 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 09950-330010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040)





9. REMOVE OIL SEAL AND OIL SLINGER
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
b. Remove the oil slinger.





10. REMOVE FRONT BEARING
Using SST, remove the front bearing from the drive pinion.
SST 09556-22010
If the front bearing is damaged or worn, replace the bearing.





11. REMOVE DIFFERENTIAL CASE ASSEMBLY
a. Place matchmarks, on the bearing cap and differential carrier.
b. Remove the 2 bolts and adjusting nut locks.
c. Remove the 4 bolts, 2 bearing caps and adjusting nuts.

HINT: Tag the disassembled parts to show the location for reassembling.

d. Remove the differential case with the bearing outer races from the carrier.

HINT: Tag the disassembled parts to show the location for reassembling.

12. REMOVE DRIVE PINION AND BEARING SPACER FROM DIFFERENTIAL CARRIER
a. Remove the drive pinion with the rear bearing.
b. Remove the bearing spacer.





13. REMOVE DRIVE PINION REAR BEARING
a. Using SST and a press, remove the rear bearing from the drive pinion.
SST 09950-00020

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

b. Remove the plate washer from the drive pinion.





14. REMOVE FRONT AND REAR BEARING OUTER RACES
Using a brass bar and hammer, remove the outer races.





15. REMOVE RING GEAR
a. Place matchmarks on the ring gear and differential case.
b. Remove the 12 ring gear set bolts.
c. Using a plastic hammer, tap on the ring gear to remove it from the differential case.
16. CHECK DIFFERENTIAL CASE RUNOUT
a. Place the bearing outer races on their respective bearings. Check that the right and left outer races are not interchanged.
b. Install the differential case in the differential carrier.
c. Tighten the adjusting nut just to where there is no play in the bearing.
d. Align the matchmarks on the bearing cap and differential carrier.
e. Install and uniformly tighten the 4 bearing cap bolts a little at a time.





f. Using a dial indicator, measure the differential case runout.

Maximum case runout: 0.04 mm (0.0016 inch)

g. Remove the differential case.





17. REMOVE SIDE BEARINGS FROM DIFFERENTIAL CASE
Using SST, remove the 2 side bearings from the differential case.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00480)





18. DISASSEMBLE DIFFERENTIAL CASE
a. Place matchmarks on the RH and LH differential cases.
b. Remove the 8 bolts uniformly, a little at a time.
c. Using a plastic hammer, separate the RH and LH differential cases.
d. Remove the 2 side gear thrust washers, 2 side gears, spider, 4 pinion gears and pinion gear thrust washers.

REPLACEMENT





1. REMOVE COMPANION FLANGE DUST DEFLECTOR
Using SST, a steel plate and press, remove the dust deflector.
SST 09950-00020





2. INSTALL DUST DEFLECTOR
Using SST, a steel plate and press, install a new dust deflector.
SST 09726-40010

REASSEMBLY

HINT:
^ Using a shop rag, clean off any foreign object from the parts.
^ Apply all of the sliding and rotating surfaces with hypoid gear oil.

1. MEASURE SIDE GEAR BACKLASH





a. Install the 2 thrust washers to the side gears.
b. Install the side gear to the differential case.
c. Install the 4 pinion gears and thrust washers to the spider.
d. Install the spider assembly to the differential case.

HINT: Install the spider to the differential case tightly.





e. Using a dial indicator, measure the side gear backlash holding the side gear and spider.

Backlash: 0.02 - 0.15 mm (0.0008 - 0.0059 inch)

HINT:
^ Measure at all 4 locations.
^ Measure the backlash at the RH and LH differential cases.

If the backlash is not within the specified value, install a thrust washer of a different thickness.





Thrust washer thickness:

2. ASSEMBLE DIFFERENTIAL CASE
a. Reinstall the spider to the differential case.

HINT: Install the spider to the differential case tightly.





b. Align the matchmarks and assemble the RH and LH differential cases.
c. Tighten the 8 bolts uniformly, a little at a time.

Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)

3. INSTALL SIDE BEARINGS





a. Using Special Service Tool (SST) and a press, install the RH side bearing on the differential case.
SST 09710-30050, 09950-70010 (09951-07100)





b. Using SST and a press, install the LH side bearing on the differential case.
SST 09710-30050, 09950-60010 (09951-00480), 09950-70010 (09951-07100)
4. INSTALL RING GEAR ON DIFFERENTIAL CASE
a. Clean the threads of the bolts and differential case with the white gasoline.
b. Clean the contact surfaces of the differential case and ring gear.





c. Heart the ring gear to about 100°C (212°F) in boiling water.
d. Carefully take the ring gear out of the boiling water.
e. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.





f. Align the matchmarks on the ring gear and differential case.
g. Temporarily install the 12 set bolts.
h. After the ring gear cools down enough, torque the 12 set bolts to which thread lock has been applied.

Thread lock: Part No. 08833-00100, THREE BOND 1360 K or equivalent

Torque: 137 Nm (1,400 kgf-cm, 101 ft. lbs.)

5. CHECK RING GEAR RUNOUT
a. Place the bearing outer races on their respective bearings. Check that the right and left outer races are not interchanged.
b. Install the differential case onto the carrier and tighten the adjusting nut just to where there is no play in the bearings.





c. Using a dial indicator, check the ring gear runout.

Maximum runout: 0.05 mm (0.0020 inch)

d. Remove the differential case.





6. INSTALL FRONT AND REAR BEARING OUTER RACES
a. Using SST and a press, install the front bearing outer race.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
b. Using SST and a press, install the rear bearing outer race.
SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)
7. INSTALL DRIVE PINION REAR BEARING
a. Install the plate washer on the drive pinion.

HINT: First fit a washer with the same thickness as the washer which was removed, 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 rear bearing onto the drive pinion.
SST 09506-35010
8. TEMPORARILY ADJUST DRIVE PINION PRELOAD
a. Install the drive pinion and front bearing.

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

b. Install the oil slinger.





c. Install the companion flange with SST.
SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040)





d. Using SST to hold the flange and adjust the drive pinion preload by tightening the companion flange nut.
SST 09330-00021

NOTICE:
^ Coat the nut and screw of the drive pinion with gear oil.
^ As there is no spacer, tighten the nut a little at a time, being careful not to overtighten.





e. Using a torque wrench, measure the preload.

Preload (at starting):
New bearing 1.3 - 1.8 Nm (113 - 19 kgf-cm, 11.5 - 15.9 inch lbs.)
Reused bearing 0.64 - 0.92 Nm (6.5 - 9.4 kgf-cm, 5.7 - 8.1 inch lbs.)

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

9. INSTALL DIFFERENTIAL CASE IN CARRIER
a. Place the 2 bearing outer races on their respective bearings. Make sure that the right and left outer races are not interchanged.
b. Install the differential case in the carrier.

HINT: Make sure that there is backlash between the ring gear and drive pinion.





10. INSTALL ADJUSTING NUTS
Install the 2 adjusting nuts on the carrier, making sure the nuts are engaged properly.





11. INSTALL BEARING CAPS
Align the matchmarks on the bearing cap and carrier. Screw the 2 bearing cap bolts 2 or 3 turns and press down the bearing, cap by hand.

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

12. ADJUST SIDE BEARING PRELOAD





a. Torque the 4 bolts.

Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.)





b. Then loosen them to the point where the adjusting nuts can be turned by SST.
SST 09504-00011
c. Tighten the 4 bolts.

Torque: 9.8 Nm (100 kgf-cm, 7 ft. lbs.)

d. Using SST, torque the adjusting nut on the ring gear side until the ring gear has a backlash of about 0.2 mm (0.008 inch).





e. While turning the ring gear, use the SST to fully tighten the adjusting nut on the drive pinion side. After the bearings are settled, loosen the adjusting nut on the drive pinion side.





f. Place a dial indicator on the top of the adjusting nut on the ring gear side.
g. Adjust the side bearing to zero preload by tightening the other adjusting nut until the pointer on the indicator begins to move.





h. Using the SST, torque the adjusting nut 1 - 1.5 notches from the zero preload position.





i. Using a dial indicator, adjust the ring gear backlash until it is within the specified value.

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)

HINT: The backlash is adjusted by turning the right and left adjusting nuts by equal amount. For example, loosen the nut on the left side 1 notch and torque the nut on the right side 1 notch.





j. Torque the 4 bearing cap bolts.

Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.)

k. After rotating the ring gear 5 turns or more, recheck the ring gear backlash.

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)





13. MEASURE TOTAL PRELOAD
Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

Preload (at starting):
Drive pinion preload plus 0.38 - 0.63 Nm (3.9 - 6.5 kgf -cm, 3.3 - 5.6 inch lbs.)





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. Turn the companion flange, in both directions to inspect the ring gear for proper tooth contact.








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





Plate washer thickness:

15. REMOVE COMPANION FLANGE
16. REMOVE OIL SLINGER AND FRONT BEARING





17. REMOVE BEARING OUTER RACE
Using SST, remove the bearing outer race.
SST 09308-00010
18. INSTALL NEW BEARING SPACER





19. INSTALL BEARING OUTER RACE
Using SST and a hammer, install the bearing outer race.
SST 09316-60011 (09316-00011, 09316-00021)
20. INSTALL FRONT BEARING AND OIL SLINGER
21. INSTALL OIL SEAL
a. Coat the hypoid gear oil to a new oil seal periphery.





b. Using SST and a hammer, install the oil seal.
SST 09214-76011

Oil seal drive in depth: 0.5 mm (0.020 inch)

c. Coat MP grease to the oil seal lip.
22. INSTALL COMPANION FLANGE





a. Using SST, install the companion flange.
SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040)
b. Coat the threads of a new nut with gear oil.





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

Torque: 245 Nm (2,500 kgf-cm, 181 ft. lbs.)

23. 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 1.3 - 1.8 Nm (13 - 19 kgf-cm, 11.5 - 15.9 inch lbs.)
Reused bearing 0.64 - 0.92 Nm (6.5 - 9.4 kgf-cm, 5.7 - 18.1 inch lbs.)

If the preload is greater than the specified value, replace the bearing spacer.





If the preload is less than the specified value, retighten the nut with a force of 13 Nm (130 kgf-cm, 9 ft. lbs.) at a time until the specified preload is reached.
SST 09330-00021

Torque: 441 Nm (4,500 kgf-cm, 326 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 loosen the pinion nut to reduce the preload.
24. RECHECK RING GEAR BACKLASH
25. RECHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
26. CHECK RUNOUT OF COMPANION FLANGE
27. STAKE DRIVE PINION NUT





28. INSTALL ADJUSTING NUT LOCKS
a. Install 2 new nut locks on the bearing caps.
b. Tightening 2 bolts, bend the nut locks.

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

29. REMOVE DIFFERENTIAL CARRIER FROM OVERHAUL STAND ETC.