Disassembly and Assembly

EXPLODED VIEW

DISASSEMBLY
1. Remove differential carrier cover.
a. Remove the 8 bolts from the carrier cover.
b. Using a brass bar and hammer, separate the cover and carrier.




2. Check runout of companion flange.
Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
Maximum runout: 0.10 mm (0.0039 inch)




3. Check ring gear runout.
Using a dial indicator, check the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
If the runout is greater than the maximum, replace with a new ring gear.




4. Check ring gear backlash.
Using a dial indicator, check the backlash of the ring gear.
Backlash: 0.13-0.18 mm (0.0051-0.0071 inch)
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.
5. Check tooth contact between ring gear and drive pinion.




6. 2 Pinion differential:
Check side gear backlash.
Using a dial indicator, check the backlash of the side gear with holding 1 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, install the 2 side gear thrust washers of different thickness.




7. Measure drive pinion preload.
Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting): 0.5-0.8 Nm (4.3-6.9 inch lbs.)
8. Check total preload.
Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus: 0.3-0.5 Nm (2.6-4.3 inch lbs.)
If necessary, disassemble and inspect the differential.




9. Remove companion flange.
a. Using a chisel and hammer, unstake 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, 0995-03040, 09956-03020), remove the companion flange.




10. Remove front oil seal and oil slinger.
a. Using SST 09308-10010, remove the oil seal from the housing.
b. Remove the oil slinger.




11. Remove front bearing and bearing spacer.
a. Using SST 09550-22010, remove the front bearing from the drive pinion.
b. Remove the bearing spacer.




12. Torque Sensing Limited Slip Differential (LSD):
Remove side gear shafts.
a. Using SST 09520-24010, remove the 2 side gear shafts from the differential.
b. Using a screwdriver, remove the 2 snap rings from the 2 side gear shafts.




13. 2 Pinion Differential:
Remove side gear shafts.
a. Using needle nose pliers, remove the 2 snap rings from the 2 side gear shafts.
b. Remove the 2 side gear shafts.




14. Remove side gear shaft oil seals.
Using SST 09308-00010, remove the 2 oil seals from the housing.




15. Remove differential case.
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 4 bolts and 2 bearing caps.




c. Using SST 09504-22011 and a hammer, remove the 2 plate washers.

HINT: Measure the plate washer and note down the thickness.

d. Remove the differential case and 2 bearing outer races from the carrier.

HINT: Tag the 2 bearing outer races to show the location for reassembling.

16. Remove drive pinion from differential carrier.




17. Remove drive pinion rear bearing.
a. Using SST 09950-00020 and a press, remove the bearing from the drive pinion.

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

b. Remove the plate washer.




18. Remove front and rear bearing outer races.
Using a brass bar and hammer, remove the 2 outer races from the carrier.




19. Remove ring gear.
a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver and hammer, unstake the 4 lock plates.
c. Remove the 8 ring gear set bolts and 4 lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.




20. Remove side bearings.
Using SST 09950-00020 and a press, remove the 2 side bearings from the differential case.

NOTICE: Be careful not to drop the differential case.





21. 2 Pinion Differential Only:
Disassemble differential case.

NOTICE: If equipped with Torque Sensing LSD, do not disassemble the differential case.




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

SIDE GEAR SHAFT DUST COVER REPLACEMENT
1. Remove dust cover.
Using a screwdriver and hammer, remove the dust cover.




2. Install dust cover.
Using a steel plate and press, install a new dust cover to the side gear shaft.

NOTICE: Be careful not to damage the dust cover.

ASSEMBLY
1. 2 Pinion differential:
Adjust differential side gear backlash.




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

HINT: Select 2 thrust washers which will ensure that the backlash is within the specification.

Thrust washer thickness:
0.93 - 0.97 mm (0.0366 - 0.0382 inch)
0.98 - 1.02 mm (0.0386 - 0.0402 inch)
1.03 - 1.07 mm (0.0406 - 0.0421 inch)
1.08 - 1.12 mm (0.0425 - 0.0441 inch)
1.13 - 1.17 mm (0.0445 - 0.0461 inch)
1.18 - 1.22 mm (0.0465 - 0.0480 inch)
b. Install the 2 side gears, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft in the differential case.

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




c. Measure the side gear backlash with holding 1 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, install the 2 side gear thrust washers with different thicknesses.




2. 2 Pinion differential:
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 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 the 4 lock plates and 8 bolts.
g. After the ring gear cools down enough, torque the 8 bolts uniformly a little at a time.
Torque: 97 Nm (71 ft. lbs.)
h. Using a chisel and hammer, stake the 4 lock plates.

HINT: 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.




4. Install side bearings.
Using SST 09710 - 22021 (09710 - 01031) and a press, install the 2 side bearings into the differential case.
5. Inspect ring gear runout.
a. Install the differential case on the carrier, and install the 2 plate washers to where is no play in the bearing.
b. Install the bearing caps.




c. Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
d. Remove the 2 bearing caps, 2 plate washers and differential carrier.




6. Install front and rear bearing outer races.
a. Front side:
Using SST 09950 - 60020 (09951 - 00790), 09950 - 70010 (09951 - 07150) and a press, install the 2 outer races to the carrier.
b. Rear side:
Using SST 09950 - 60020 (09951 - 00710), 00950 - 70010 (09951 - 07150) and a press, install the 2 outer races to the carrier.
7. Install drive pinion rear bearing.
a. Install the reused washer on the drive pinion.




b. Using SST 09506 - 30012 and a press, install the rear bearing onto the drive pinion.
8. Temporarily adjust drive pinion preload.




a. Install the drive pinion and front bearing.

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




b. Using SST 09950 - 30010 (09951 - 03010, 09953 - 0301, 09954 - 03010, 09955 - 03040, 09956 - 03020), install the companion flange.
c. Coat the threads of the nut with MP grease.




d. Adjusting the drive pinion preload by tightening the companion flange nut.
Using SST 09330 - 00021 to hold the flange, torque the nut.
Torque: 108 Nm (80 ft. lbs.)

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




e. Using a torque wrench, measure the preload.
Preload (at starting):
New bearing: 1.0 - 1.6 Nm (8.7 - 13.9 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (4.3 - 6.9 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 races are not interchanged.
b. Install the differential case in the carrier.
10. Adjust ring gear backlash.
a. Install only the plate washer on the ring gear back side. Snug down the washer and bearing by tapping on the ring gear with a plastic hammer.




c. Using a dial indicator, hold the side bearing boss on the teeth surface of the ring gear and measure the ring gear backlash.
Backlash (reference): 0.13 mm (0.0051 inch)
d. Select a ring gear back side plate washer so that backlash is 0.13 mm (0.0051 inch).




e. Select a ring gear teeth side washer with a thickness which eliminates any clearance between the outer race and case.
f. Remove the plate washer and differential case.
g. Install the plate washer into the ring gear back side.




h. Place the outer plate washer onto the differential case together with the outer race, and install the differential case with the outer race into the carrier.
i. Using a plastic hammer, snug down the washer and bearing by tapping the ring gear.




j. Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
k. If it is not within the specification, adjust it by either increasing or decreasing the number of washers on both sides by an equal amount.

HINT: There should be clearance between the plate washer and case.

Ensure that there is ring gear backlash.
11. Adjust side bearing preload.
a. After adjustment with the ring gear backlash as reference, remove the teeth side plate washer.




b. Using a micrometer, measure the thickness of the removed plate washer.
c. Install a new washer 0.06 - 0.09 mm (0.0024 - 0.0035 inch) thicker than the removed washer.

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




d. Using a brass bar and hammer, tap in the plate washer.




e. Align the matchmarks on the cap and carrier, and install the 2 bearing caps and 4 bolts.
Torque: 78 Nm (58 ft. lbs.)




f. Recheck the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
If it is not within the specification, adjust it by either increasing or decreasing the washers on both sides by equal amounts.

HINT: The backlash will change by about 0.02 mm (0.0008 inch) with every 0.03 mm (0.0012 inch) change in the plate washer thickness.

Washer thickness:
2.26 - 2.28 mm (0.0890 - 0.0898 inch)
2.29 - 2.31 mm (0.0902 - 0.0909 inch)
2.32 - 2.34 mm (0.0913 - 0.0921 inch)
2.35 - 2.37 mm (0.0925 - 0.0933 inch)
2.38 - 2.40 mm (0.0937 - 0.0945 inch)
2.41 - 2.43 mm (0.0949 - 0.0957 inch)
2.44 - 2.46 mm (0.0961 - 0.0969 inch)
2.47 - 2.49 mm (0.0972 - 0.0980 inch)
2.50 - 2.52 mm (0.0984 - 0.0992 inch)
2.53 - 2.55 mm (0.0996 - 0.1004 inch)
2.56 - 2.58 mm (0.1008 - 0.1016 inch)
2.59 - 2.61 mm (0.1020 - 0.1028 inch)
2.62 - 2.64 mm (0.1031 - 0.1039 inch)
2.65 - 2.67 mm (0.1043 - 0.1051 inch)
2.68 - 2.70 mm (0.1055 - 0.1063 inch)




12. Measure total preload. Using a torque wrench, measure the preload.
Total preload (at starting): Drive pinion preload plus 0.3 - 0.5 Nm (2.6 - 4.3 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 contact pattern.




If the teeth are not contacting properly, select a proper washer for correction.
Washer thickness:
2.21 - 2.23 mm (0.0870 - 0.0878 inch)
2.24 - 2.26 mm (0.0882 - 0.0890 inch)
2.27 - 2.29 mm (0.0894 - 0.0902 inch)
2.30 - 2.32 mm (0.0906 - 0.0913 inch)
2.33 - 2.35 mm (0.0917 - 0.0925 inch)
2.36 - 2.38 mm (0.0929 - 0.0937 inch)
2.39 - 2.41 mm (0.0941 - 0.0949 inch)
2.42 - 2.44 mm (0.0953 - 0.0961 inch)
2.45 - 2.47 mm (0.0965 - 0.0972 inch)
2.48 - 2.50 mm (0.0976 - 0.0984 inch)
2.51 - 2.53 mm (0.0988 - 0.0996 inch)
2.54 - 2.56 mm (0.1000 - 0.1008 inch)
2.57 - 2.59 mm (0.1012 - 0.1020 inch)
2.60 - 2.62 mm (0.1024 - 0.1031 inch)
2.63 - 2.65 mm (0.1035 - 0.1043 inch)
2.66 - 2.68 mm (0.1047 - 0.1055 inch)
2.69 - 2.71 mm (0.1059 - 0.1067 inch)
2.72 - 2.74 mm (0.1071 - 0.1079 inch)
2.75 - 2.77 mm (0.1083 - 0.1091 inch)
2.78 - 2.80 mm (0.1094 - 0.1102 inch)
2.81 - 2.83 mm (0.1106 - 0.1114 inch)
2.84 - 2.86 mm (0.1118 - 0.1126 inch)
2.87 - 2.89 mm (0.1130 - 0.1138 inch)
2.90 - 2.92 mm (0.1142 - 0.1150 inch)
2.93 - 2.95 mm (0.1154 - 0.1161 inch)
2.96 - 2.98 mm (0.1165 - 0.1173 inch)
2.99 - 3.01 mm (0.1177 - 0.1185 inch)
3.02 - 3.04 mm (0.1189 - 0.1197 inch)
3.05 - 3.07 mm (0.1201 - 0.1209 inch)
3.08 - 3.10 mm (0.1213 - 0.1220 inch)
3.11 - 3.13 mm (0.1224 - 0.1232 inch)
3.14 - 3.16 mm (0.1236 - 0.1244 inch)
3.17 - 3.19 mm (0.1248 - 0.1256 inch)
3.20 - 3.22 mm (0.1260 - 0.1268 inch)
14. Remove companion flange.
15. Remove front bearing.




16. Install new bearing spacer and front bearing. Install a new bearing spacer and front bearing on the drive pinion.
17. Install oil slinger.
18. Install new front oil seal.




a. Using SST 09554 - 22010 and hammer, install a new oil seal.
Oil seal drive in depth: 2.0 mm (0.079 inch)
b. Apply MP grease to the oil seal lip.
19. Install companion flange.




a. Using SST 09950 - 30010 (09951 - 03010, 09953 - 03010, 09954 - 03010, 09955 - 03040, 09956 - 03020), install the companion flange on the drive pinion.
b. Coat the threads of a new nut with hypoid gear oil.




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




20. Check drive pinion preload.
Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting):
New bearing: 1.0 - 1.6 Nm (8.7 - 13.9 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (4.3 - 6.9 inch lbs.)
- If preload is greater than the specification, replace the bearing spacer.




- If preload is less than the specification, retorque the nut 13 Nm (9 ft. lbs.) at a time until the specified preload is reached.
If the maximum torque is exceeded while retighten the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the pinion nut to reduce the preload.
Maximum Torque: 235 Nm (174 ft. lbs.)
21. Recheck total preload.
22. Recheck ring gear backlash.
23. Recheck tooth contact between ring gear and drive pinion.
24. Check companion flange runout.
25. Stake drive pinion nut.
26. Install side gear shaft oil seals.




a. Using SST 09550 - 00032, 09950 - 70010 (09951 - 07150) and a hammer, install 2 oil seals until they are flush with the carrier end surface.
b. Coat MP grease to the oil seal lip.
27. Install side gear shafts.

Torque Sensing LSD:
a. Install 2 new snap rings to the side gear shafts.




b. Using SST 09520 - 24010, install the 2 side gear shafts until it contacts the pinion shaft.

HINT: Check that the shaft is fully inserted by confirming the noise it should make when it is tapped.

2 Pinion Differential:
a. Install the 2 side gear shafts to the differential case.




b. Install 2 new snap rings to the 2 side gear shafts.




28. Install differential carrier cover.
a. Clean contacting surfaces of any residual Formed In Place Gasket (FIPG) material using gasoline or alcohol.
b. Apply FIPG to the carrier.
FIPG: THREE BOND 1281 or equivalent.

HINT: Install the carrier cover within 3 minutes after applying FIPG.

c. Torque the 8 bolts.
Torque: 47 Nm (34 ft. lbs.)