Rear Differential Carrier Assembly

REAR DIFFERENTIAL CARRIER ASSEMBLY

Components:

REMOVAL
1. REMOVE REAR WHEEL
Torque: 131 Nm (1,340 kgf-cm, 97 ft. lbs.)
2. DRAIN DIFFERENTIAL OIL
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

3. DISCONNECT BRAKE LINE
a. Using SST, disconnect the brake line and remove the clip.
SST 09023-00101
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)

HINT: Use the same procedures described for the other side.

4. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY
a. Remove the 2 clips, pin and disconnect the parking brake cable from the bell crank.

HINT: Use the same procedures described for the other side.

5. REMOVE REAR AXLE SHAFT LH
a. Remove the 4 nuts.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
b. Pull out the axle shaft and remove the O-ring.

NOTICE: Be careful not to damage the oil seal.

6. REMOVE REAR AXLE SHAFT RH

HINT: Use the same procedures described for the LH side.

7. DISCONNECT REAR PROPELLER SHAFT ASSEMBLY
a. Place matchmarks on the propeller shaft and differential flange.
b. Remove the 4 nuts, 4 bolts and 4 washers, and disconnect the propeller shaft.
Torque: 106 Nm (1,080 kgf-cm, 78 ft. lbs.)
c. Support the propeller shaft securely

8. REMOVE REAR DIFFERENTIAL CARRIER SUB ASSEMBLY
a. Remove the 10 nuts, washers and differential carrier assembly.

NOTICE: Be careful not to damage the installation surface.

Torque: 72 Nm (740 kgf-cm, 53 ft. lbs.)
b. Remove the gasket.

DISASSEMBLY
1. FIX REAR DIFFERENTIAL CARRIER SUB ASSEMBLY

2. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
a. Using dial indicator, measure the vertical and lateral 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, 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. INSPECT RING GEAR BACKLASH
a. Using a dial indicator, measure the ring gear backlash.
Standard backlash: 0.13 to 0.18 mm (0.0051 to 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. 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) 0.71 to 0.99 Nm (7.2 to 10.1 kgf-cm, 6.3 to 8.8 inch lbs.)
6. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the total preload with the teeth of the drive pinion and ring gear in contact.
Torque: Standard total preload (at start of torque) 0.38 to 0.63 Nm (3.9 to 6.5 kgf-cm, 3.4 to 5.6 inch lbs.)
If necessary, disassemble and inspect the differential.
7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
8. REMOVE REAR 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, 09956-03040)

9. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
b. Remove the oil seal.
10. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Remove the oil slinger.

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

12. REMOVE REAR DIFFERENTIAL CASE SUB-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.

13. 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 is damaged, replace them as a set.

b. Remove the plate washer from the drive pinion.

14. REMOVE BEARING OUTER RACE
a. 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. INSPECT 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 the point 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 runout: 0.04 mm (0.0016 inch)
g. Remove the differential case.

17. REMOVE REAR DIFFERENTIAL CASE BEARING
a. 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. REMOVE 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-faced 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 REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST, a steel plate and press, remove the dust deflector.
SST 09950-00020

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

REASSEMBLY

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

1. INSPECT 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.
Standard backlash: 0.02 to 0.15 mm (0.0008 to 0.0059 inch)

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

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

Standard 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 REAR DIFFERENTIAL CASE BEARING
a. Using 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, 09950-70010 (09951-07100), 09950-60010 (09951-00480)
4. INSTALL RING GEAR
a. Clean the threads of the bolts and differential case with the white gasoline.
b. Clean the contact surface of the differential case an ring gear.

c. Heat 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. INSPECT 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 the point 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 BEARING OUTER RACE
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 REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Install the plate 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 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 09950-30012 (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 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.

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 REAR DIFFERENTIAL BEARING ADJUSTING NUT
a. Install the 2 bearing nuts on the carrier, making sure the nuts are engaged properly

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

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

h. Using SST, torque the adjusting nut 1 to 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.
Standard backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)

HINT: The backlash is adjusted by turning the right and left adjusting nuts by an 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.
Standard backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)

13. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Torque: Standard preload (at start of torque) 0.38 to 0.63 Nm (3.9 to 6.5 kgf-cm, 3.3 to 5.6 inch lbs.) + drive pinion

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.

Standard Plate Washer Thickness:

15. REMOVE DRIVE PINION COMPANION FLANGE SUB ASSEMBLY
16. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
17. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

18. REMOVE BEARING OUTER RACE
a. Using SST, remove the bearing outer race.
SST 09308-00010
19. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

20. INSTALL BEARING OUTER RACE
a. Using SST and a hammer, install the bearing outer race.
SST 09316-60011 (09316-00011, 09316-00021)
21. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
22. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
23. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
a. Coat a new oil seal periphery with hypoid gear oil.

b. Using SST and a hammer, install the oil seal.
SST 09214-76011
Standard depth: 0.5 mm (0.020 inch)
c. Coat the lip of the oil seal with MP grease.

24. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
a. Using SST, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040)
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.)

25. ADJUST DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

Standard Preload (at Start Of Torque):

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

b. 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 exceed while retightening nut, replace the bearing spacer and repeat the preload procedure. Do not loosen the pinion nut to reduce the preload.
26. INSPECT RING GEAR BACKLASH
27. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
28. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
29. STAKE DRIVE PINION NUT
30. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK
a. Install 2 new nut locks on the bearing caps.
b. Tighten the 2 bolts and bend the 2 nut locks.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)

INSTALLATION
Installation is in the reverse order of removal.

HINT: After installation, fill the differential with hypoid gear oil, fill the brake reservoir with brake fluid, bleed the brake system, check for leaks and check for the ABS speed sensor signal.