Front Differential Carrier Assembly

FRONT DIFFERENTIAL CARRIER ASSEMBLY

Components:

REMOVAL
1. REMOVE FRONT WHEEL
Torque: 131 Nm (1,340 kgf-cm, 97 ft. lbs.)
2. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
a. Remove the front drive shaft.
3. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
a. Remove the front drive shaft.

4. DISCONNECT FRONT PROPELLER SHAFT ASSEMBLY
a. Place matchmarks on the propeller shaft and companion flange.
b. Remove the 4 nuts, bolts and washers, and disconnect the propeller shaft.
Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.)
c. Support the propeller shaft securely
5. DRAIN HYPOID GEAR OIL
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

6. REMOVE NO. 3 FRAME CROSSMEMBER SUB ASSEMBLY
a. Remove the 5 bolts, 5 nuts, 4 washers and No. 3 frame crossmember.
Torque:
186 Nm (1,900 kgf-cm, 137 ft. lbs.) for bolt
68 Nm (695 kgf-cm, 50 ft. lbs.) for nut
7. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY
a. Support the front differential carrier assembly with a jack.
b. Remove the bolt and disconnect the breather hose.
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)

c. Remove the 3 nuts, 4 mount stoppers, 6 bolts, 2 differential supports and front differential carrier assembly.
Torque:
186 Nm (1,900 kgf-cm, 137 ft. lbs.) for bolt A
78 Nm (800 kgf-cm, 58 ft. lbs.) for bolt B

DISASSEMBLY
1. REMOVE FRONT DIFFERENTIAL CARRIER COVER
a. Remove the 9 bolts and nut from the carrier cover.
b. Using a brass bar and hammer, separate the cover from the carrier.
c. Remove the breather plug from the differential carrier cover.
d. Remove the 2 bolts and oil deflector from the differential carrier cover.

2. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
a. Using a dial indicator, measure the vertical runout of the companion flange.
Maximum runout: 0.14 mm (0.0055 inch)
If the runout is greater than the maximum, replace the companion flange.

3. INSPECT RING GEAR RUNOUT
a. Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.07 mm (0.0028 inch)
If the runout is greater than the maximum, replace the ring gear and drive pinion as a set.

4. INSPECT RING GEAR BACKLASH
a. Using a dial indicator, while holding the drive pinion flange measure the ring gear backlash.
Standard backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)

HINT: Measure at 3 or more places on the circumference of the ring gear. If the backlash is not within the specification, adjust the backlash.

5. INSPECT DRIVE PINION PRELOAD
a. Using a torque wrench, measure the drive pinion preload using the backlash of the drive pinion and ring gear.
Torque: Standard preload (at start of torque) 0.6 to 0.9 Nm (6 to 9 kgf-cm, 4.3 to 6.9 inch lbs.)
6. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the total preload.
Torque: Standard total preload (at start of torque) 0.4 to 0.6 Nm (4 to 6 3.5 to 5.2 kgf-cm, inch lbs.) + drive pinion preload
If necessary, disassemble and inspect the differential.
7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

8. REMOVE SIDE GEAR SHAFT OIL SEAL
a. Using SST, remove the 2 side gear shaft oil seals.
SST 09308-00010

9. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY
a. Using SST, remove the snap ring.
SST 09350-30020 (09350-07060)
b. Using a snap ring expander, remove the snap ring.
c. Remove the 4 bolts and differential tube with side gear shaft from the differential carrier.
d. Remove the side gear shaft from the differential tube.

10. REMOVE DIFFERENTIAL SIDE GEAR SHAFT BEARING
a. Using SST and a press, remove the bearing from side gear shaft.
SST 09950-60010 (09951-00410), 09950-70010 (09951-07100)
11. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
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 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

12. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
13. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Remove the oil slinger.

14. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST, remove the rear bearing from the drive pinion.
SST 09556-22010
If the rear bearing is damaged or worn, replace the rear bearing.

15. REMOVE FRONT DIFFERENTIAL CASE SUB-ASSEMBLY
a. Place 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 side bearing plate washers.
SST 09504-22011

HINT: Measure the plate washer and note the thickness.

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

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

16. REMOVE DRIVE PINION SUB-ASSEMBLY
17. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

18. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST and a press, remove the front 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 washer.

19. REMOVE REAR BEARING OUTER RACE
a. Using SST, remove the rear bearing outer race.
SST 09308-00010

b. Using a brass bar and hammer, remove the oil storage ring and front bearing outer race.

20. REMOVE DIFFERENTIAL RING GEAR
a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver and hammer, unstake the 5 lock plates.
c. Remove the 10 bolts and 5 lock plates.
d. Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.
21. INSPECT DIFFERENTIAL CASE
a. Place the bearing outer races on their respective bearings. Check that the left and right outer races are not interchanged.
b. Install the assembled plate washers onto the side bearing.
c. Install the differential case in the differential carrier.

HINT: If it is difficult to install the differential case into the carrier, replace the plate washer with a thinner one. However, select a plate washer that allows no clearance between it and the carrier.

d. Align matchmarks on the bearing cap and differential carrier.
e. Install and uniformly tighten the 4 bolts a little at a time.

f. Using a dial indicator, measure the differential case runout.
Maximum runout: 0.07 mm (0.0028 inch)
If the runout is greater that the maximum, replace the differential case and side bearings as a set.
g. Remove the differential case.

22. REMOVE FRONT DIFFERENTIAL CASE BEARING
a. Using SST, remove the 2 side bearings from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00480)

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

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

REPLACEMENT

1. REPLACE FRONT DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, remove the dust deflector.
SST 09950-00020, 09950-60010 (09951-00400), 09950-70010 (09951-07100)

b. Using SST and a press, install a new dust deflector.
SST 09223-00010

REASSEMBLY

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

1. ASSEMBLE DIFFERENTIAL CASE
a. Install the 2 side gear thrust washers to the side gears.
b. Install the 2 side gears to the RH case.
c. Install the 4 pinion gears and pinion gear thrust washers to the spider.
d. Install the pinion gears with the spider to the RH case.

e. Using a dial indicator, holding the side gear and spider, measure the side gear backlash.
Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 inch)

HINT:
^ Measure at all 4 locations.
^ Measure the backlash at the specification, and install a thrust washer of a different thickness.

Standard Thrust Washer Thickness:

f. Align the matchmarks on the LH and RH cases.
g. Torque the 8 bolts uniformly a little at a time.
Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)
2. 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 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. Temporarily install 5 new lock plates and 10 bolts so that the bolt holes in the ring gear and differential cases are not misaligned.
f. After the ring gear has cooled sufficiently, torque the 10 ring gear set bolts.
Torque: 97 Nm (985 kgf-cm, 71 ft. lbs.)

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

HINT: Stake the claws of the lock plates to fix the bolts. For the claw contacting the protruding portion of the bolt in place, stake only the half of it along the tightening direction.

3. INSTALL FRONT DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the 2 side bearings to the differential case.
SST 09223-15020, 09950-60010 (09951-00480)
4. INSPECT RING GEAR RUNOUT
a. Place the bearing outer races on their respective bearings. Check that the left and right outer races are not interchanged.
b. Install the assembled plate washers onto the side gear bearing.
c. Install the differential case in the differential carrier.

HINT: If it is difficult to install the differential case into the carrier, replace the plate washer with a thinner one. However, select a plate washer that allows no clearance between it and the carrier.

d. Align matchmarks on the bearing cap and differential carrier.
e. Install and uniformly tighten the 4 bolts a little at a time.

f. Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.07 mm (0.0028 inch)
g. Remove the differential carrier.

5. INSTALL BEARING OUTER RACE
a. Using SST and a press, install the front bearing outer race.
SST 09950-60020 (09951-00780), 09950-70010 (09951-07150)
b. Using SST and a press, install the rear bearing outer race.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
6. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Install the washer on the drive pinion.

HINT: First fit a washer with the same thickness as the washer that 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 front bearing onto the drive pinion.
SST 09506-30012
7. TEMPORARILY ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Install the drive pinion and rear bearing.

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

b. Install the oil slinger.

c. Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

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

NOTICE:
^ Coat the nut and threads 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 it.

e. Using a torque wrench, measure the preload.

Standard Preload (at Start Of Torque):

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

8. INSTALL FRONT DIFFERENTIAL CASE
a. Place the bearing outer races on their respective bearings. Check that the left and right outer races are not interchanged.
b. Install the differential case in the differential carrier.
9. ADJUST RING GEAR BACKLASH
a. Install the plate washer on the ring gear back side.

HINT: Make sure that the ring gear has backlash.

b. Tap on the ring gear with a plastic-faced hammer so that the washer fits to the bearing.
c. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.
Standard backlash (reference): 0.13 mm (0.0051 inch)
d. Select a plate washer for the back side ring gear, using the backlash as reference.

Standard Side Plate Washer Thickness:

e. Select a ring gear teeth side plate washer so that there is no clearance between the outer race and case.

f. Remove the 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. Tap on the ring gear with a plastic-faced hammer so that the washers fit to the bearing.

j. Using a dial indicator, measure the ring gear backlash.
Standard backlash: 0.13 to 0.18 mm (0.0051 to 0.0070 inch)
If the backlash is not within the specification, adjust it by either increasing or decreasing the thickness of 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.

10. ADJUST FRONT DIFFERENTIAL CASE BEARING
a. Remove the ring gear teeth side plate washer and measure the thickness.

b. Using the backlash as a reference, install a new washer that is 0.06 to 0.09 mm (0.0024 to 0.0035 inch) thicker than the washer removed.

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

c. Using a plastic-faced hammer, install the plate washer.
d. Align matchmarks on the bearing cap and differential carrier.
e. Tighten the 4 bolts.
Torque: 85 Nm (870 kgf-cm, 63 ft. lbs.)

HINT: Turn the ring gear several times to make the side bearings smooth.

f. Using a dial indicator, adjust the ring gear backlash until it is within the specification.
Standard backlash: 0.13 to 0.18 mm (0.0051 to 0.0070 inch)
If the backlash is not within the specification, adjust it by either increasing or decreasing the thickness of the washers on both sides by an equal amount.

HINT: The backlash will change by about 0.02 mm (0.0008 inch) corresponding to a 0.03 mm (0.0012 inch) change in the plate washer.

11. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the total preload.
Torque: Standard total preload (at start of torque) 0.4 to 0.6 Nm (4 to 6 kgf-cm, 3.5 to 5.2 inch lbs.) + drive pinion preload

12. 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.

Standard Washer Thickness:

13. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
14. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
15. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
16. REMOVE BEARING OUTER RACE
17. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install a new bearing spacer.

18. INSTALL FRONT DIFFERENTIAL OIL STORAGE RING
a. Using SST and a hammer, install a new oil storage ring.
SST 09316-60011 (09316-00011), 09506-35010

19. INSTALL BEARING OUTER RACE
a. Using SST and a hammer, install the bearing outer race.
SST 09316-60011 (09316-00011), 09506-35010
20. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
21. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
22. INSTALL FRONT DIFFERENTIAL CASE OIL SEAL
a. Coat a new oil seal periphery with hypoid gear oil.

b. Using SST and a hammer, install a new oil seal.
SST 09554-30011
Standard depth: 1.5 mm (0.0059 inch)
c. Coat the lip of the oil seal with MP grease.

23. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
a. Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
b. Coat the threads of a new with hypoid gear oil LSD.

c. Using SST to hold the flange, tighten the nut.
SST 09330-00021
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
24. ADJUST DRIVE PINION PRELOAD
a. Using a torque wrench, measure the drive pinion preload using the backlash of the drive pinion and ring gear.

Standard Preload (at Start Of Torque):

If the preload is greater than the specification, replace the bearing spacer.

b. If the preload is less than the specification, 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: 370 Nm (3,773 kgf-cm, 273 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.
25. INSPECT TOTAL PRELOAD
26. INSPECT RING GEAR BACKLASH
27. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
28. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
29. STAKE DRIVE PINION NUT

30. INSTALL DIFFERENTIAL SIDE GEAR SHAFT BEARING
a. Using SST and a press, install the bearing to the side gear shaft.
SST 09502-12010, 09950-60020 (09951-00730), 09950-70010 (09951-07100)
31. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY
a. Clean surfaces with FIPG material attached to using gasoline or alcohol.
b. Apply FIPG to the differential tube.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent.

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

c. Install the differential tube to the differential tube the with 4 bolts.
Torque: 105 Nm (1,070 kgf-cm, 77 ft. lbs.)
d. Install the side gear shaft.
e. Install a snap ring expander, install the snap ring.

f. Using SST, install the snap ring.
SST 09350-30020 (09350-07060)
32. INSTALL SIDE GEAR SHAFT OIL SEAL
a. Coat a new oil seal periphery with hypoid gear oil.

b. SST and a hammer, install 2 new oil seals.
SST 09550-00032, 09950-70010 (09951-07150)
c. Coat the lip of the oil seal with MP grease.
33. INSTALL FRONT DIFFERENTIAL CARRIER COVER
a. Install the oil seal deflector to the carrier cover with the 2 bolts.
Torque: 7.3 Nm (74 kgf-cm, 64 inch lbs.)
b. Install the breather plug to the carrier cover.
c. Remove any oil FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and carrier cover.
d. Clean the contacting surfaces of any FIPG material using gasoline or alcohol.

e. Apply FIPG to the carrier cover, as shown.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent.

HINT: Install the carrier cover within 10 minutes after applying FIPG.

f. Install the differential carrier cover with the 9 bolts.
Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.)

INSTALLATION
Installation is in the reverse order of removal.

HINT: After installation, fill the differential with hypoid gear oil.