Without Differential Lock

DISASSEMBLY









HINT: Pre runner is the model described.
RZN191L-TRPDKAB, RZN196L-CRPDKAB, PZN196L-PRPDKAB, VZN195L-CRPDKAB, VZN195L-PRPDKAB





1. CHECK COMPANION FLANGE RUNOUT
Using a dial indicator, measure the vertical and lateral runout on the companion flange.
Maximum: runout: 0.09 mm (0.0035 inch)
If the runout exceeds the maximum, replace the companion flange.





2. CHECK RING GEAR RUNOUT
Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 inch)
If the runout exceeds the maximum, replace the ring gear.





3. CHECK RING GEAR BACKLASH
Using a dial indicator, while holding the companion flange, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)

HINT: Measure 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 as necessary.

4. CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION





5. CHECK SIDE GEAR BACKLASH
Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specified value, replace the side gear thrust washer of the different thickness.





6. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the drive pinion using the backlash between the drive pinion and ring gear.
Preload (at starting): 0.6 - 0.9 Nm (7 - 10 kgf-cm, 5.7 - 8.3 inch lbs.)
7. 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 0.4 - 0.6 Nm (4 - 6 kgf-cm, 3.5 - 5.2 inch lbs.)
If necessary, disassemble and inspect the differential.
8. REMOVE COMPANION FLANGE
a. Using a chisel and hammer, unstake the staked part of the nut.





b. Using Special Service Tool (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, 09956-03050)





9. REMOVE FRONT OIL SEAL
Using SST, remove the oil seal from the differential carrier.
SST 09350-32014 (09308-10010)





10. REMOVE FRONT BEARING AND BEARING SPACER
a. Using SST remove the bearing from the drive pinion.
SST 09556-22010
If the front bearing is damage or worn, replace the front bearing.
b. Remove the 2 washers and bearing spacer.
11. REMOVE DIFFERENTIAL CASE





a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 4 bolts and bearing cap.





c. Using SST and a plastic hammer, remove the 2 side bearing plate washers.
SST 09504-22011

HINT: Measure the plate washer and note down the thickness.

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

HINT: Tag the bearing outer races to show the location for reassembling.

12. REMOVE DRIVE PINION FROM DIFFERENTIAL CARRIER
Remove the drive pinion with the rear bearing.





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

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





14. REMOVE FRONT AND REAR BEARING OUTER RACES AND ADJUSTING WASHER

NOTICE: Do not remove the outer races except when replacing the bearings.

Using a brass bar and hammer, remove the outer races and adjusting washer from the carrier.

HINT: Measure the adjusting washer and note down the thickness.





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 separate it from the differential case.





16. CHECK DIFFERENTIAL CASE RUNOUT
a. Install the differential case in the differential carrier.
b. Using a dial indicator, measure the differential case runout.
Maximum case runout: 0.04 mm (0.0016 inch)
c. Remove the differential case.





17. 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, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00480)

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





18. DISASSEMBLE DIFFERENTIAL CASE ASSEMBLY
a. Using a pin punch and hammer, remove the straight pin.
b. Remove the pinion shaft, 2 pinion gears, pinion gear thrust washers, side gears and side gear thrust washers from the differential case.

REPLACEMENT
REPLACE COMPANION FLANGE DUST DEFLECTOR





a. Using Special Service Tool (SST), a socket wrench and a press, remove the dust, deflector.
SST 09950-00020





b. Using SST and a press, install a new dust deflector.
SST 09523-36010

REASSEMBLY
1. ASSEMBLE DIFFERENTIAL CASE





a. Install the 2 thrust washer to the side gears.

HINT: Refer to the table to select thrust washers which will ensure that the backlash is within the specifications.





Washer thickness:

b. Install the 2 side gears with the thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft.

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: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specified value, select an appropriate thickness for the side gear thrust washer.





d. Using a pin punch and hammer, install the straight pin through the holes in the differential case and pinion shaft.
e. Using a chisel and hammer, stake the out side of the differential case pin hole.





2. INSTALL SIDE BEARINGS
Using Special Service Tool (SST) and a press, install the 2 side bearings into the differential case.
SST 09950-60010 (09951-00480, 09951-00640) 09950-70010 (09951-07150)
3. 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 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 to the differential case.

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

e. After the ring gear cools down enough, torque the set bolts to which thread lock has been applied.
Thread lock: Part No. 08833-00100, THREE BOND 1360K or equivalent.
Torque: 125 Nm (1,270 kgf-cm, 92 ft. lbs.)





4. INSPECT RING GEAR RUNOUT
a. Install the differential case into the carrier and install the plate washers to where there is no play in the bearing (See step 8.).
b. Install the bearing cap (See step 11.).
c. Using a dial indicator, measure the runout of ring gear.
d. Remove the bearing caps and differential case.
Maximum runout: 0.05 mm (0.0020 inch)





5. INSTALL DRIVE PINION BEARING OUTER RACES AND ADJUSTING WASHER
a. Using SST and a press, install a new front bearing outer race to the carrier.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
b. Using SST and a press, install a new adjusting washer and a new rear bearing outer race to the carrier.
SST 09950-60020 (09951-00910), 09950-70010 (09951-07150)

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.





6. INSTALL DRIVE PINION REAR BEARING
Using SST and a press, install the rear bearing onto the drive pinion.
SST 09506-35010
7. TEMPORARILY ADJUST DRIVE PINION PRELOAD
a. Install the drive pinion and front bearing.

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





b. Using SST, install the companion flange.
SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03050)
c. Coat the threads of the nut with hypoid gear oil.





d. Adjust the drive pinion preload by tightening the companion flange nut.

HINT: Using SST to hold the flange, torque 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 of the drive pinion using the backlash between the drive pinion and ring gear.
Preload (at starting):
New bearing: 1.1 - 1.7 Nm (12 - 18 kgf-cm, 10.0 - 15.2 inch lbs.)
Reused bearing: 0.6 - 0.9 Nm (7 - 10 kgf-cm, 5.7 - 8.3 inch lbs.)
8. INSTALL DIFFERENTIAL CASE IN CARRIER
a. Place the 2 bearing outer races on their respective bearings. Make sure the right and left races are not inter changed.
b. Install the differential case in the carrier.
9. ADJUST RING GEAR BACKLASH





a. Only install the plate washer on the ring gear back side.

HINT: Make sure that the ring gear has a backlash.





b. Using a plastic hammer, snug down the plate washer and bearing by tapping the ring gear.





c. Using a dial indicator, hold the side bearing boss on the teeth surface of the ring gear and measure the backlash.
Backlash (reference): 0.13 - 0.18 mm (0.0051 - 0.0071 inch)





d. Select a plate washer for back side ring gear using the backlash as reference.





e. Select a ring gear teeth side plate washer of a thickness which eliminates any clearance between the outer race and case.
f. Remove the 2 plate washers and differential case.
g. Install the plate washer into the ring gear back side of the carrier.





h. Place the other plate washer onto the differential case together with the outer race, and install the differential case with the outer race into the carrier.
i. Using a plastic hammer, snug down the washer and bearing by tapping the ring gear.





j. Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
k. If the backlash is not within the specified value, adjust by either increasing or decreasing the thickness of washers on both sides by an equal amount.

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

10. ADJUST SIDE BEARING PRELOAD





a. After adjustment with the backlash as reference, remove the ring gear teeth side plate washer and measure the thickness.
b. Install a new washer of 0.06 - 0.09 mm (0.0024 - 0.0035 inch) thicker than the washer which was removed.

HINT: Select a washer which can be pressed in 2/3 of the way by finger.

c. Using a plastic hammer, install the plate washer.





d. Recheck the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
e. If the backlash is not within the specification, adjust by either increasing or decreasing the thickness of washers on both sides by equal amount.

HINT: The backlash will change by about 0.20 mm (0.0079 inch) with every 0.03 mm (0.0012 inch) change in the side washer.





Washer Thickness:

11. INSTALL SIDE BEARING CAP
a. Align the matchmarks on the cap and carrier.
b. Install and torque the 4 bolts.
Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.)





12. MEASURE 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 0.4 - 0.6 Nm (4 - 6 kgf-cm, 3.5 - 5.2 inch lbs.)
13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION





a. Coat 3 or 4 teeth at three different positions on the ring gear with red lead primer.
b. Hold the companion flange firmly and rotate the ring gear in both directions.





c. Inspect the teeth pattern.





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





Washer thickness:

14. REMOVE COMPANION FLANGE
15. REMOVE FRONT BEARING





16. INSTALL NEW BEARING SPACER, 2 WASHERS AND FRONT BEARING
a. Install a new bearing spacer and 2 washers, and place the front bearing.
b. Using SST and the companion flange, install the front bearing then remove the companion flange.
SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03050)





17. INSTALL NEW OIL SEAL
a. Coat a new oil seal lip with MP grease.
b. Using SST and a plastic hammer, install the oil seal until its surface is flush with the differential carrier end.

SST 09316-12010, 09649-17010

HINT: Connect SST with vinyl tape.





18. INSTALL COMPANION FLANGE
a. Place the companion flange.
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: 147 Nm (1,500 kgf-cm, 109 ft. lbs.)





19. ADJUST DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the drive pinion using the backlash between the drive pinion and ring gear.
Preload (at starting):
New bearing: 1.1 - 1.7 Nm (112 - 18 kgf-cm, 10.0 - 15.2 inch lbs.)
Reused bearing: 0.6 - 0.9 Nm (7 - 10 kgf-cm, 5.7 - 8.3 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 13 Nm (130 kgf-cm, 9 ft. lbs.) a little at a time until the specified preload is reached.
Torque: 451 Nm (4,600 kgf-cm, 333 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.





20. 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 0.4 - 0.6 Nm (4 - 6 kgf-cm, 3.5 - 5.2 inch lbs.)
21. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
22. RECHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See step 13.)
23. CHECK COMPANION FLANGE RUNOUT
24. STAKE DRIVE PINION NUT