Assembly

1. Inspect the sleeve by:
a. Installing the sleeve to the differential case (LH) and check to see if it moves smoothly.
b. Installing the sleeve to the side gear and check to see if it moves smoothly.





2. Measure clearance of shift fork and sleeve by using a feeler gauge and measuring the clearance between the shift fork and sleeve. The clearance, (for reference) should be 0.15 - 0.35 mm (0.006 - 0.014 inch).
3. Assemble differential case by performing the following.
a. Apply all of the sliding and rotating surfaces with gear oil.
b. Install the 2 side gear thrust washers to the side gears.





c. Install the side gear to the RH case.
d. Install the four pinion gears and pinion gear thrust washers to the spider.
e. Install the pinion gear with the spider to the RH case.





f. Using a dial indicator, measure the side gear backlash with holding the side gear and spider, it should measure 0.05 - 0.20 mm (0.0020 - 0.0079 inch).

NOTE: Measure at all 4 locations then measure the backlash at the RH case and at the LH case. If the backlash is not within the specification, install a thrust washer of a different thickness.

Thrust Washer Thickness
0.9 mm (0.035 inch).
1.0 mm (0.039 inch).
1.1 mm (0.043 inch).
1.2 mm (0.047 inch).
1.3 mm (0.051 inch).

g. Install the side gear and side gear thrust washer to the RH case.
h. Install the pinion gears and spider to the RH case.
i. Install the side gear and side gear thrust washer to the RH case.
j. Align the matchmarks on the LH and RH cases.





k. Torque the eight bolts uniformly to 47 Nm (35 ft. lbs.) a little at a time.





4. Using SST 09223-15020, 09950-60010 (09950-00480) and a press, install the 2 side bearings on the differential case.
5. To install the ring gear on differential case do the following.
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 remove the ring gear from 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 new lock plates and set bolts.

NOTE: The ring gear set bolts should not tighten until the ring gear has cooled sufficiently.





g. After the ring gear cools down enough, tighten the set bolts to 97 Nm (71 ft. lbs.) uniformly, and a little at a time.





h. Using a drift punch and hammer, stake the lock plates. Stake one claw 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.

6. Check ring gear runout by:
a. Installing the differential case onto the carrier and tightening the adjusting nut just to where there is no play in the bearings.





b. Using a dial indicator, check the ring gear runout. The maximum runout should measure 0.10 mm (0.0039 inch).
c. Remove the differential case.





7. Using the 09316 - 60011 (09316 - 00011, 09316 - 00021) SSTs and a hammer, install a new oil storage ring.





8. Install the drive pinion front and rear bearing outer races by using the 09316 - 60011 (09316 - 00011, 09316 - 00051) SSTs for the front and the 09316 - 60011 (09316 - 00011, 09316-00021) SSTs for the rear side and a press to install the 2 outer races.
9. Install the drive pinion front bearing by:
a. Installing the plate washer on the drive pinion with the chamfered end facing the pinion gear.





b. Using the 09506 - 30012 SST and a press, install the front bearing onto the drive pinion.

10. Temporarily adjust drive pinion preload by performing the following.
a. Install the drive pinion, rear bearing and oil slinger and assemble the spacer and oil seal after adjusting the gear contact pattern.





b. Install the companion flange with the 09550 - 30010 (09951 - 03010, 09953 - 03010, 09954-03010, 09955-03030, 09956-03020) SSTs.





c. Adjust the drive pinion preload by tightening the companion flange nut. Using the 09330 - 00021 SST to hold the flange, tighten the nut.

NOTE: As there is no spacer, tighten a little at a time, being careful not to overtighten.

d. Using a torque wrench, measure the preload. For a new bearing it should measure 0.9-1.6 Nm (8.7 - 13.9 inch lbs.) and for a reused bearing it should measure 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.) Measure the total preload after first turning the bearing clockwise and counterclockwise several times to mark the bearing smooth.





11. Install differential case into carrier by performing the following:
a. Apply MP grease on the rack of the shift fork and connecting part of the indicator switch.
b. Insert the shift fork into the differential carrier, as shown.





c. Install the 2 outer races, adjusting nuts and left side to the sleeve and check that the sleeve moves smoothly.
d. Install the shift fork in the groove of the sleeve holding it by hand and install the case in the carrier then make sure that there is backlash between the ring gear and drive pinion.





12. Align the matchmarks on the cap and carrier. Screw in the 2 bearing cap bolts 2 or 3 turns and press down the bearing cap by hand.

NOTE: If the bearing cap does not fit tightly on the carrier, the adjusting nuts are not threaded properly. Reinstall the adjusting nuts if necessary.

13. Adjust side bearing preload by performing the following procedures.
a. Torque the 4 bearing cap bolts to 78 Nm (58 ft. lbs.), and loosen them to the point where the adjusting nuts can be turned by the 09504 - 000 11 Special Service Tool (SST).
b. Fully tighten the 4 bearing cap bolts by hand.





c. Using the SST, torque the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008 inch).





d. With 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.
e. Place a dial indicator on the top of the adjusting nut on the ring gear side.
f. Adjust the side bearing for zero preload by tightening the other adjusting nut until the pointer on the indicator begins to move.





g. Torque the adjusting nut 1 to 1.5 notches from the zero preload position.





h. Using a dial indicator, adjust the ring gear backlash until it is within the specification of 0.13 - 0.18 mm (0.0051 - 0.0071 inch)

NOTE: The backlash is adjusted by turning the left and right adjusting nuts equal amounts. For example, loosen the nut on the left side one notch and torque the nut on the right side one notch.

i. Torque the 4 bearing cap bolts to 78 Nm (58 ft. lbs.).
j. Recheck the ring gear backlash to 0.13 - 0.18 mm (0.0051 - 0.0071 inch).





k. Using a torque wrench, measure the preload, the starting preload should be 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.).





14. Inspect the tooth contact between the ring gear and drive pinion by performing the following.
a. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead.
b. Hold the companion flange firmly and rotate the ring gear in both directions.





c. Inspect the tooth pattern.





d. Inspect the tooth pattern and if the teeth are not contacting properly, use the following chart to select a proper washer for correction.

Washer Thickness
1.70 mm (0.0669 inch).
1.73 mm (0.0681 inch).
1.76 mm (0.0693 inch).
1.79 mm (0.0705 inch).
1.82 mm (0.0717 inch).
1.85 mm (0.0728 inch).
1.88 mm (0.0740 inch).
1.91 mm (0.0752 inch).
1.94 mm (0.0764 inch).
1.97 mm (0.0776 inch).
2.00 mm (0.0787 inch).
2.03 mm (0.0799 inch).
2.06 mm (0.0811 inch).
2.12 mm (0.0835 inch).
2.15 mm (0.0846 inch).
2.18 mm (0.0858 inch).
2.21 mm (0.0870 inch).
2.30 mm (0.0906 inch).
2.33 mm (0 0917 inch).

15. Remove companion flange.
16. Remove oil slinger and rear bearing.
17. Remove rear bearing outer race and oil storage ring.





18. Install the bearing spacer and rear bearing by performing the following:
a. Install a new bearing spacer on the shaft.
b. Install a new oil storage ring and rear bearing outer race.
c. Install the rear bearing and oil slinger.





19. Using the 09214 - 76011 SST and a hammer, install a new oil seal, as shown. The oil seal drive in depth is 1.0 mm (0.039 inch). Apply MP grease to the oil seal lip.





20. Install the companion flange by following the steps listed below.
a. Install the companion flange by using the 09550 - 30010 (09951 - 03010, 09953 - 03010, 09954 - 03010, 09955 - 03030, 09956 - 03020) SSTs.
b. Install the plate washer and a new nut taking care to coat the threads of a new nut with hypoid gear oil.





c. Using the 09330 - 00021 SST to hold the flange then tighten the nut to 196 Nm (145 ft. lbs.).





21. Adjust the drive pinion preload by using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. The starting preload should be 0.9 - 1.6 Nm (8.7 - 13.9 inch lbs.) for a new bearing, and 0.5-0.8 Nm (4.3 - 6.9 inch lbs.) for a reused bearing. If the preload is greater than the specification, replace the bearing spacer. If the preload is less than the specification, retighten the nut a little at a time with a torque of 13 Nm (19 ft. lbs.) until the specified preload is reached. If the maximum torque of 343 Nm ( 253 ft. lbs.) is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the pinion nut to reduce the preload.
22. Recheck ring gear backlash.
23. Recheck tooth contact between ring gear and drive pinion.
24. Check runout of companion flange.
25. Stake drive pinion nut.





26. Install 2 new nut locks on the bearing caps and tighten them to 13 Nm (9 ft. lbs.). After tightening bolts, bend the nut locks.
27. Install the shift fork shaft if the vehicle has a w/differential lock by performing the following.
a. Apply MP grease onto the outer circuit of the fork shaft.





b. Install the fork shaft to match the hole of the shift fork and that of the shift fork shaft.
c. Remove any FIPG material and be careful not to drop oil on the contacting surface of the differential carrier and shaft retainer.





d. Apply FIPG part no. 08826-00090, THREE BOND 1281 or equivalent to the carrier, as shown taking care to install the shaft retainer within 10 minutes after applying the FIPG.
e. Clean the threads of the bolts and retainer bolts holes with toluene or trichloroethylene.





f. Apply adhesive, part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent to 2 or 3 threads of the mount bolt end.
g. Tighten the shaft retainer with the 2 bolts to 24 Nm (17 ft. lbs.).





h. Using a pin punch and hummer, install the slotted spring pin to the shift fork.





i. Shift the fork deeply and keep the differential lock condition.
j. Install the ball, compression spring and spring seat.
k. Clean the threads of 2 plugs and plug holes with toluene or trichloroethylene.





l. Apply adhesive, part no. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent to the plug threads.
m. Using a hexagon wrench, install and tighten the screw plugs to 22 Nm (16 ft. lbs.).





28. Measure the distance between sleeve and differential case end side by measuring the distance between the sleeve and tip of the differential case when differential is free and locked. The standard distances are as follows:
^ LOCK: 17.44- 18.86 mm (0.6866 - 0.7425 inch).
^ FREE: 32.40 - 33.90 mm (1.2756 -1.3346 inch).





29. Install the indicator switch with a new gasket and tightening it to 40 Nm (30 ft. lbs.).





30. Install the actuator by performing the following.
a. Check that the outermost rack tooth of the shift fork is virtually above the center line of the actuator installation hole.





b. Ensure that the matchmarks of the pinion of the actuator is in the extent between 0 and 5° clockwise above the center line of the actuator.

NOTE: If the matchmarks is not in this extent, rotate the pinion to be matched,do not supply the battery positive voltage directly between terminals and if the matchmarks come to the extension limit of the rotation, do not electrify moreover.





c. Install a new O-ring to the actuator.
d. Apply a light coat of gear oil on the O-ring.
e. Apply MP grease to the gear part.
f. Insert the actuator so that the long hole on the actuator side fits with the knock pin on the carrier side taking care to not damage the O-ring of the actuator.





g. Align the actuator with the long hole and rotate the actuator counterclockwise when the knock pin reaches the right-hand side.





h. Install the actuator to the differential carrier with the bolt so that the outermost rack tooth of the shift fork will fit the matchmarks of the pinion of the actuator torquing to 26 Nm (20 ft. lbs.).