Part 2

DIFFERENTIAL CARRIER ASSEMBLY REAR (4WD)
OVERHAUL
34. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
35. REMOVE DIFFERENTIAL CASE ASSEMBLY





a. Align matchmarks on the bearing cap and differential carrier.
b. Remove the 4 bolts and 2 bearing caps.





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

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





d. Remove the differential case assembly and the 2 bearing outer races from the differential carrier.

HINT: Tag the 2 bearing outer races to show the location for reassembling.

36. REMOVE DIFFERENTIAL DRIVE PINION





37. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER 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 are damaged, replace them as a set.

b. Remove the plate washer.





38. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, remove the front bearing (outer race) from the carrier.





39. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, remove the rear bearing (outer race) from the carrier.





40. REMOVE DIFFERENTIAL RING GEAR
a. Align matchmarks on the ring gear and differential case.
b. Using a screwdriver and a hammer, unstake the 4 lock plates.
c. Remove the 8 ring gear set bolts and 4 lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.





41. INSPECT RUNOUT OF DIFFERENTIAL CASE ASSEMBLY
a. Install the differential case in the differential carrier.
b. Install the right and left bearing caps with the 4 bolts.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.)
c. Using a dial indicator, measure the differential case run out.
Maximum case runout: 0.07 mm (0.0028 inch)
d. Remove the differential case.





42. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the case bearing (LH) from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)





43. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the case bearing (RH) from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)
44. REMOVE REAR DIFFERENTIAL PINION SHAFT





a. Using a pin punch (5 mm) and a hammer, remove the straight pin.





b. Remove the differential pinion shaft. [A]
c. Remove the 2 differential pinions. [B]
d. Remove the 2 differential pinion thrust washers. [C]
e. Remove the 2 side gears. [D]
f. Remove the 2 side gear thrust washers. [E]
45. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
a. Check that no damage is identified on the differential pinion and side gear. If the differential pinion and/or side gear is damaged, replace them with new ones.
46. INSPECT DIFFERENTIAL CASE
a. Check that no damage is identified in the differential case. If the differential case is damaged, replace the differential case.





47. INSTALL REAR DIFFERENTIAL PINION SHAFT
a. Install the 2 thrust washers on the 2 side gears.
b. Install the 2 side gears, 2 differential pinions, 2 differential pinion thrust washers and differential pinion shaft in the differential case.

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

48. ADJUST DIFFERENTIAL PINION GEAR BACKLASH





a. Install the side gear shaft.
b. Measure the side gear backlash while holding 1 pinion gear toward the differential case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specification, install the 2 side gear thrust washers with different thicknesses.

HINT:
^ Measure the backlash of the side gear with the side gear shaft installed.
^ Refer to the following table to select 2 thrust washers which ensures that the backlash is within the specification.





Thrust washer thickness

c. Remove the side gear shaft.





d. Using a pin punch (5 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft.
e. Using a chisel and a hammer, stake the outside of the differential case pin hole.
49. INSTALL DIFFERENTIAL RING GEAR





a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear to approximately 100°C (212°F) in the 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.





e. Align the matchmarks on the ring gear and differential case.
f. Temporarily install 4 new lock plates and 8 bolts.
g. After the ring gear cools down enough, 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 over several times.





h. Using a chisel and a hammer, stake the 4 lock plates.

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





50. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the case bearing (RH) into the differential case.
SST 09636-20010





51. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the case bearing (LH) into the differential case.
SST 09636-20010





52. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
a. Install the differential case on the carrier, and install the 2 plate washers so that there is no play in the bearing.
b. Install the 2 bearing caps with the 4 bolts.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.)
c. Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
d. Remove the 2 bearing caps, 2 plate washers and differential carrier.





53. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST and a press, install the front bearing (outer race) to the carrier.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)





54. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, install the rear bearing (outer race) to the carrier.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)





55. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Install the removed plate washer on the drive pinion.
b. Using SST and a press, install the rear bearing onto the drive pinion.
SST 09506-30012
56. ADJUST DIFFERENTIAL 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, as shown in the illustration.





c. Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
d. Coat the threads of the nut with hypoid gear oil LSD.





e. Using SST to hold the flange, torque the nut.
SST 09330-00021
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)

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





f. Using a torque wrench, measure the preload.
Preload (at starting):
New bearing: 1.1 - 1.7 Nm (11 - 17 kgf-cm, 9.6 - 14.8 inch lbs.)
Reused bearing: 0.6 - 0.9 Nm (6 - 9 kgf-cm, 5.2 - 7.8 inch lbs.)
57. INSTALL DIFFERENTIAL CASE ASSEMBLY
a. Place the 2 bearing outer races on their respective bearings. Make sure the right and left races are not interchanged.





58. ADJUST DIFFERENTIAL RING GEAR BACKLASH
a. Install the right and left bearing caps with the 4 bolts.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.)

HINT:
^ If the side bearing is new, select a thrust shim of proper thickness from the thinner ones.
^ If the side bearing is reused, select a thrust shim of the same thickness as the one installed before disassembly.

b. Snug down the differential case bearing and thrust shim by tapping on the ring gear with a plastic hammer.
c. Set the dial indicator perpendicular to the end of the ring gear face.
d. While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.
Backlash:0.13 - 0.18 mm (0.0051 - 0.0071 inch)

NOTICE: Measure it at 3 points or more on the ring gear periphery.

If the measured value is out of the specified value, select a proper thrust shim so that the backlash of the differential ring gear is within the value, and install it to the ring gear back side.





Washer thickness

59. ADJUST TOTAL PRELOAD
a. After adjusting the backlash of the differential ring gear, remove the teeth side thrust shim.
b. Using a micrometer, measure the thickness of the removed thrust shim.
c. Select a new thrust shim 0.06 - 0.09 mm (0.0024 - 0.0035 inch) thicker than the removed one.

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





d. Using SST and a plastic hammer, drive in the thrust shim.
SST 09504-22011
e. Align matchmarks on the bearing cap and differential carrier, install the 2 bearing caps.

NOTICE: Make sure the right and left bearing caps are not inter-changed.

f. Tighten the both bearing caps with the 4 bolts.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.)





g. Set the dial indicator to the end of the differential ring gear face.
h. While holding the rear drive pinion companion flange rear, rotate the differential ring gear and measure the backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
i. If the measured value is out of the specified value, adjust it by increasing or decreasing the thickness of both right and left thrust shims equally.
SST 09504-22011





j. Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus 0.3 - 0.5 Nm (3 - 5 kgf-cm, 2.6 - 4.3 inch lbs.)
60. 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.





c. Inspect the tooth contact pattern.





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





Washer thickness

61. REMOVE REAR DRIVE PINION NUT (See step 28)
SST 09330-00021
62. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR (See step 29)
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
63. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
64. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (See step 33)
SST 09556-22010
65. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install a new bearing spacer.





66. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Install the rear drive pinion front tapered roller bearing on the drive pinion.