Disassembly and Assembly

DISASSEMBLY
1. Remove companion flange.
a. Using a chisel and hammer, loosen the staked part of the nut.





b. Using Special Service Tool (SST) # 09330 - 00021 or equivalent to hold the flange, remove the nut.





c. Using SST # 09950 - 30010 (09951 - 03010, 09953 - 03010, 09954 - 03010, 09955 - 03030, 09956 - 03020) or equivalents, remove the companion flange.
2. Remove front oil seal and oil slinger.





a. Using SST # 09308 - 10010 or equivalent, remove the oil seal from the housing.
b. Remove the oil slinger.
3. Remove front bearing and bearing spacer.





a. Using SST # 09556 - 22010 or equivalent, remove the bearing from the drive pinion.
b. Remove the bearing spacer.
4. Remove differential case.





a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 2 adjusting nut locks.
c. Remove the 4 bolts and 2 bearing caps.
d. Remove the 2 adjusting nuts.
e. Remove the differential case with the side bearing outer races from the differential carrier.

HINT: Tag the disassembled parts to show the location for reassembly.

5. Remove drive pinion. Remove the drive pinion with the rear bearing.





6. Remove drive pinion rear bearing. Using SST # 09950 - 00020 or equivalent and a press, remove the bearing from the drive pinion.

HINT: If the drive pinion or ring gear are damaged, replace them as a set.





7. Remove front and rear bearing outer race.

NOTICE: Do not remove the outer races except when replacing the bearings.

Using a brass bar and hammer, remove the outer race from the carrier.
8. Remove ring gear.





a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver, unstake the lock plates.
c. Remove the 10 bolts and 5 lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
9. Check differential case runout.
a. Place the 2 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.
c. When there is not play left in the side bearings, install the plate washers.
d. Align the matchmarks on the bearing cap and differential carrier.
e. Install and uniformly tighten the 4 bearing cap bolts in several passes.





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





10. Remove side bearings. Using SST # 09950 - 40010 (09951 - 04010, 09952 - 04010, 09953 - 04020, 09954 - 04010, 09955 - 04060, 09957 - 04010, 09958 - 04010), 09950 - 60010 (09951 - 00450) or equivalents, remove the 2 side bearings from the differential case.

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

11. Disassemble differential case assembly.





a. Using a pin punch and hammer, remove the straight pin.
b. Remove these parts from the differential case:
1) Pinion shaft.
2) 2 pinion gears.
3) 2 pinion gear thrust washers.
4) 2 side gears.
5) 2 side gear thrust washers.


COMPANION FLANGE DUST DEFLECTOR REPLACEMENT





1. Remove dust deflector. Using Special Service Tool (SST) # 09950 - 00020 or equivalent, a socket wrench and press, remove the dust deflector.





2. Install new dust deflector. Using SST # 09636 - 20010 or equivalent and a press, install a new dust deflector.


ASSEMBLY
1. Adjust differential side gear backlash.





a. Install the 2 proper thrust washers on the side gears.

HINT: Using the table below, select thrust washers which will ensure that the backlash is within the specification.

Washer thickness:
1.0 mm (0.039 inch)
1.1 mm (0.043 inch)
1.2 mm (0.047 inch)
1.3 mm (0.051 inch)

b. Install the 2 side gears, pinion gears, pinion gear thrust washers and pinion shaft in the differential case.

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





c. Using a dial indicator, measure the side gear backlash with holding one 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, select an appropriate thickness for the side gear thrust washer.





2. Install straight pin and stake differential case.
a. Using a pin punch and hammer, install the straight pin through the differential case and hole of the pinion shaft.
b. Using a chisel and hammer, stake the outside of the differential case pin hole.
3. Install ring gear on differential case.
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.





HINT: Align the matchmarks on the ring gear and the differential case.

e. Temporarily install 5 new lock plates and the 10 bolts so that the bolt holes in the ring gear and differential case are not misaligned.

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

f. After the ring gear has cooled sufficiently, torque the 10 ring gear set bolts.
Torque: 97 Nm (71 ft. lbs.)





g. Using a drift punch and hammer, stake the lock plates.

HINT: Stake one claw flush with the flat surface of the nut. For the claw contacting the protruding portion of the nut, stake the half on the tightening side.





4. Install side bearings. Using Special Service Tool (SST) # 09550 - 10012 (09557 - 10010), 09950 - 60010 (09951 - 00450), 09950 - 70010 (09951 - 07150) or equivalents and a press, install the bearing into the, differential case.





5. Check ring gear runout.
a. Install the differential case in the differential carrier and tighten the adjusting nut just to where there is no play in the bearing.
b. Using a dial indicator, measure the runout of ring gear.
Maximum runout: 0.07 mm (0.0028 inch)





6. Install drive pinion bearing outer races. Using SST and a press, install the outer races.
Front: SST 09950 - 60010 (09951 - 00410), 09950 - 70010 (09951 - 07150) or equivalents.
Rear: SST 09950 - 60020 (09951 - 00750), 09950 - 70010 (09951 - 07150) or equivalents.
7. Install drive pinion rear bearing.
a. Install the plate washer on the drive pinion.

HINT: First fit a washer with the same thickness as the washer which was removed, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.





b. Using SST # 09506 - 30012 or equivalent and a press, install the rear bearing to the drive pinion.
8. Temporarily adjust drive pinion preload.
a. Place the drive pinion and front bearing.

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

b. Install the oil slinger.





c. Using SST # 09950 - 30010 (09951 - 03010, 09953 - 03010, 09954 - 03010, 09955 - 03030, 09956 - 03020) or equivalents, install the companion flange.
d. Coat the threads of the nut with gear oil.
e. Adjust the drive pinion preload by tighten the companion flange nut.





HINT: Using SST # 09330 - 00021 or equivalent to hold the flange, tighten the nut.

NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.





f. Using a torque wrench, measure the drive pinion preload.
Preload (at starting):
New bearing: 1.4 - 2.1 Nm (12.2 - 18.3 inch lbs.)
Reused bearing: 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.)





9. Install differential case in carrier.
a. Place the 2 bearing outer races on their respective bearings. Make sure the left and right outer races are not interchanged.
b. Install the case in the carrier.

HINT: Make sure that there is a backlash between the ring gear and drive pinion.

10. Install adjusting nuts. Install the 2 adjusting nuts on the carrier, making sure the nuts are threaded properly.





11. Install bearing caps. 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.

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

12. Adjust side bearing preload.
a. Tighten the 4 bearing cap bolts to the specified torque, then loosen them to the point where they can be turned by hand.
Torque: 85 Nm (63 ft. lbs.)
b. Fully tighten the 4 bearing cap bolts by hand.





c. Using SST # 09504 - 00011 or equivalent, tighten the adjusting nut on the ring gear back side until the ring gear has a backlash of about 0.2 mm (0.008 inch).
d. With turning the ring gear, use SST # 09504 - 00011 or equivalent to fully tighten the adjusting nut on the ring gear teeth 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 back 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. Tighten the adjusting nut 1 - 1.5 notches from the zero preload position.





h. Using a dial indicator, adjust the ring gear backlash until it is within the specification.
Backlash: 0.13 - 0.18 mm (0.0061 - 0.0071 inch)

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

i. Torque the 4 bearing cap bolts.
Torque: 85 Nm (83 ft. lbs.)
j. Recheck the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)





k. Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.)
13. 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.
b. Hold the companion flange firmly and rotate the ring gear in both directions.





c. Inspect the tooth pattern.





If the teeth are not contacting properly, use the following chart to select a proper washer for correction.
Thickness:
2.24 mm (0.0882 inch)
2.27 mm (0.0894 inch)
2.30 mm (0.0906 inch)
2.33 mm (0.0917 inch)
2.36 mm (0.0929 inch)
2.39 mm (0.0941 inch)
2.42 mm (0.0953 inch)
2.45 mm (0.0965 inch)
2.48 mm (0.0976 inch)
2.51 mm (0.0988 inch)
2.54 mm (0.1000 inch)
2.57 mm (0.1012 inch)
2.60 mm (0.1024 inch)
2.63 mm (0.1035 inch)
2.66 mm (0.1047 inch)
2.69 mm (0.1059 inch)
2.72 mm (0.1071 inch)

14. Remove companion flange and oil slinger.
15. Remove front bearing.
16. Install new bearing spacer, front bearing and oil slinger.
a. Install a new bearing spacer and place the front bearing and oil slinger.





b. Using SST # 09950 - 30010 (09951 - 03010, 09953 - 03010, 09954 - 03010, 09955 - 03030, 09956 - 03020) or equivalents and the companion flange, install the front bearing then remove the companion flange.
17. Install new oil seal.
a. Coat a new oil seal lip with Multipurpose (MP) grease.





b. Using SST # 09554 - 30011 or equivalent and a hammer, install the oil seal.
Oil seal drive in depth: 1.5 mm (0.059 inch)
18. Install companion flange.
a. Place the companion flange.
b. Coat the threads of a new nut with gear oil.





c. Using SST # 09330 - 00021 or equivalent to hold the flange, torque the nut.
Torque: 108 Nm (80 ft. lbs.)





19. Adjust drive pinion preload. Using a torque wrench, measure the preload of the backlash between the drive pinon and ring gear.
Preload (at starting):
New bearing: 1.4 - 2.1 Nm (12.2 - 18.3 inch lbs.)
Reused bearing: 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.)
^ If the preload is greater than the specification, replace the bearing spacer.
^ If the preload is less than the specification, retighten the nut 13 Nm (9 ft. lbs.) a little at a time until the specified preload is reached.
Maximum torque: 235 Nm (174 ft. lbs.)
If the maximum torque is exceeded while retightening the nut, replace the spacer and repeat the preload procedure. Do not back off the nut to reduce the preload.
20. Check runout of companion flange.
21. Stake drive pinion nut.





22. Install adjusting nut locks.
a. Select either a lock No. 1 or No. 2, whichever will fit the 2 adjusting nuts.
b. Install 2 new nut locks on the bearing caps.
Torque: 13 Nm (9 ft. lbs.)