Assemble

TOOLS REQUIRED
* 07746-0030100 Driver, 40 mm I.D.
* 07MAF-SP0013A Installer Shaft
* 07MAF-SP0011A Tapered Bearing Race Installer A
* 07MAF-SP0012A Tapered Bearing Race Installer B
* 07746-0010600 Attachment, 72 x 75 mm
* 07749-0010000 Driver
* 07HAJ-PK40201 Preload Inspection Tool
* 07LAD-PW50500 Pinion Cover Driver Attachment
* 07947-6110501 Driver Attachment or equivalent





NOTE:
- If replacement is required, always replace the drive pinion and ring gear as a set.
- If the drive pinion and ring gear are replaced, check the height adjustment.
Refer to Pinion Gear adjustment procedures.





1. Install the 40 mm thrust shim and tapered roller bearing using the special tool and a press as shown.
NOTE: Use a used pinion spacer with the special tool for bearing installation, and then discard the used pinion spacer.





2. Check the differential case bearing surface areas for burrs, and remove as needed. Position the inboard thrust washer into the differential case. Using the sides of the special tools stamped "B", install the inboard bearing outer race as shown. Repeat for the outboard bearing outer race.





a. First install the outboard bearing outer race.





b. Next install the inboard bearing outer race.








3. Install the 75 mm thrust shim and bearing outer race in the differential housing using the special tools as shown.
NOTE: Install the 75 mm thrust shim that was removed.








4. Install the 75 mm thrust shim and bearing outer race in the differential cover using the special tools as shown.
NOTE: Install the 75 mm thrust shim that was removed.





5. Apply lubricant to the tapered roller bearing, then install the drive pinion into the differential case as shown.
NOTE: Do not install the pinion spacer and thrust washers at this time.





6. Apply lubricant to the tapered roller bearing, then install the tapered roller bearing using the special tool, and by holding the drive pinion as shown.





7. Install the pinion collar, spring washer and locknut.
NOTE:
- The locknut has left-hand threads.
- Apply a sufficient amount of lubricant (gear oil and molybdenum disulfide in a mixing ratio of 5:1) to the locknut and the threaded part of the shaft.





8. Hold the drive pinion using a 1 1/4" (32 mm) hex bit and socket as shown, then carefully tighten the pinion locknut until there is no play in the drive pinion.
Torque: 20 Nm (14 ft. lbs.).

CAUTION: To avoid damaging the tapered roller bearing, do not overtighten the locknut.

9. Clean and paint the ring gear teeth lightly and evenly with Prussian Blue (on both sides of each tooth).
10. Apply lubricant to the tapered roller bearings, install the differential carrier into the differential case, then install the differential case cover.





11. Install the bolts and tighten in a crisscross pattern, in several steps.
Torque: 47 Nm (35 ft.lbs)





12. Install the special tool as shown. Rotate the ring gear one full turn in both directions while applying resistance to the drive pinion.
13. Remove the differential case cover, and check the tooth contact pattern (heel and toe). Adjust the ring gear-tooth contact as needed.
- Refer to Ring Gear adjustment procedures.
Ring Gear





14. After adjusting the ring gear tooth contact, remove the drive pinion, then install a new pinion spacer and thrust washers on the drive pinion.





15. Apply lubricant to the tapered roller bearing, then install it using the special tool while holding the drive pinion as shown.





16. Install a new oil seal using the special tools as shown.





17. Install the pinion collar, spring washer and locknut.
NOTE:
* The locknut has left-hand threads.
* Apply a sufficient amount of lubricant (gear oil and molybdenum disulfide in a mixing ratio of 5 : 1 ) to the locknut and the threaded part of the shaft.





18. Hold the drive pinion using a 1 1/4" (32 mm) hex bit and socket as shown.





19. Tighten the locknut to 255 Nm (188 ft. lbs.), and measure the tapered roller bearing preload.
NOTE: Rotate the drive pinion several times to ensure proper tapered roller bearing contact.

Standard:
- New Bearing: 1.27 - 1.67 Nm (11 - 15 inch lbs.)
- Reused Bearing: 0.64 - 1.03 Nm (5.6 - 9.11 inch lbs.)

* If the tapered roller bearing preload exceeds the standard, replace the pinion spacer. (See step 14.)
* If the tapered roller bearing preload is less than the standard, adjust by tightening the locknut a little at a time, but keep the torque within 255 - 324 Nm (188 - 239 ft. lbs.). If this is not possible, replace the pinion spacer. (See step 14.)


20. Clean and paint the ring gear teeth lightly and evenly with Prussian Blue (on both sides of each tooth).
21. Install the differential carrier into the differential case, and reinstall the differential case cover.
22. Install the bolts and tighten in a crisscross pattern in several steps.
Torque: 47 Nm (35 ft. lbs.).





23. Install the special tool as shown. Rotate the ring gear one full turn in both directions while applying resistance to the drive pinion.
24. Remove the special tool, and use a dial-type torque wrench on the pinion shaft to check total bearing preload.
NOTE: Rotate the drive pinion several times to ensure proper bearing contact.

NOTE: In the following measurements "Tp" is the pinion bearing preload from step 19.

Pinion and ring gear bearings are new:
- Tp plus 1.26 - 1.57 Nm (11.1 - 13.9 inch lbs.)

Pinion and ring gear bearings are reused:
- Tp plus 0.89 - 1.13 Nm (7.90 - 9.98 inch lbs.)

Ring gear bearing is new:
-11GTp plus 1.26 - 1.57 Nm (11.1 - 13.9 inch lbs.)

Pinion bearing is new:
- Tp plus 0.89 - 1.13 Nm (7.90 - 9.98 inch lbs.)

If the total preload is not within the standard, correct it by increasing or decreasing the preload on the carrier bearings as needed.
- If there is too much preload, decrease the shim thickness equal amounts on both sides.
- If there is not enough preload, increase the shim thickness equal amounts on both sides.
NOTE: Be sure the same amount of shim thickness is added or subtracted from both sides, so that the backlash and tooth contact pattern are not affected.

25. Secure the differential assembly in a vise using soft jaws.





26. Align a differential carrier rib with the 20 mm plug hole, and install the special tools as shown.





27. Measure backlash in 3 - 4 places on the differential carrier using the special tools as shown.
Standard: 0.04 - 0.10 mm (0.002-O.004 inch)
The difference among the 3 - 4 measurements taken must not exceed 0.04 mm (0.002 inch)

28. If the backlash is less then the standard, adjust the ring gear backlash.
- Refer to Ring Gear adjustment procedures.

29. Remove the differential case cover, and check the tooth contact pattern (face and flank). If the tooth contact is not correct, adjust ring gear tooth contact.
- Refer to Ring Gear adjustment procedures.





30. After all adjustments are made, install the oil collect plate and the breather chamber plate, then stake the screw heads in the groove as shown.





31. Apply liquid gasket to the mating surface of the differential case.

NOTE:
- Use liquid gasket.
- Remove the dirt and oil from the sealing surface.
- If 20 minutes have passed after applying liquid gasket, reapply it and assemble the housings, and allow it to cure at least 20 minutes after assembly before filling the transmission with oil.





32. Install the differential case cover.
Torque the bolts in a crisscross pattern, in several steps.
Torque: 47 Nm (35 ft.lbs.)





33. Install the oil seal using the special tools as shown.





34. Install the O-ring and the oil cooler.
Torque:
- Oil cooler body bolts: 27 Nm (20 ft.lbs.)
- Tube bracket bolts: 12 Nm (8.7 ft.lbs.)





35. Stake the locknut tab into the groove.





36. Install the pinion collar oil seal using the special tools as shown.