Unit Overhaul

DISASSEMBLY
1. REMOVE DIFFERENTIAL CARRIER COVER
a. Remove the 8 bolts from the carrier cover.
b. Using a brass bar and a hammer, separate the cover from the carrier.
c. Remove the breather plug from the differential carrier cover.
d. Torque sensing LSD: Remove the bolt and oil deflector from the differential.
2. CHECK RUNOUT OF COMPANION FLANGE





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





b. Place a dial indicator on the place 30 mm (1.181 inch) apart from the center of the companion flange.
c. Measure the runout of the companion flange horizontally.
Maximum runout: 0.10 mm (0.0039 inch)
3. CHECK RING GEAR





a. Check the 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 value, replace it with a new ring gear.





b. Check the 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.
4. CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION





5. 2 pinion differential:
CHECK BACKLASH OF SIDE GEAR
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.





6. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting): 0.6 - 0.9 Nm (6 - 9 kgf-cm, 5.3 - 8.0 inch lbs.)
7. CHECK TOTAL PRELOAD
Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus 0.3 - 0.5 Nm (3 - 5 kgf-cm, 2.6 - 4.3 inch lbs.)
If necessary, disassemble and inspect the differential.
8. REMOVE COMPANION FLANGE





a. Using a chisel and a hammer, unstake the staked part of 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, 09955-03040, 09956-03020)
9. REMOVE FRONT OIL SEAL AND OIL SLINGER





a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
b. Remove the oil slinger.
10. REMOVE FRONT BEARING AND BEARING SPACER





a. Using SST, remove the front bearing from the drive pinion.
SST 09556-22010
b. Remove the bearing spacer.
11. Torque sensing LSD:
REMOVE SIDE GEAR SHAFTS





a. Using SST, remove the 2 side gear shafts from the differential carrier.
SST 09520-24010 (09520-04010, 09520-32040)
b. Using a screwdriver, remove the 2 snap rings from the 2 side gear shafts.





12. 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.
13. REMOVE SIDE GEAR SHAFT OIL SEALS





Using SST, remove the 2 oil seals from the housing.
SST 09308-10010
14. 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 and a hammer, remove the 2 plate washers.
SST 09504-22012

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 of reassembling.

15. REMOVE DRIVE PINION FROM DIFFERENTIAL CARRIER
16. REMOVE DRIVE PINION REAR BEARING





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

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

b. Remove the plate washer.





17. REMOVE FRONT AND REAR BEARING OUTER RACES
Using a brass bar and a hammer, remove the 2 outer races from the carrier.





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





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

NOTICE: Be careful not to drop the differential case.





20. 2 pinion differential:
DISASSEMBLE DIFFERENTIAL CASE

NOTICE: If equipped with torque sensing LSD, do not disassemble the differential case.

a. Using a pin punch and a hammer, remove the straight pin.
b. Remove the pinion shaft, 2 pinion gears, 2 pinion gear thrust washers, 2 side gears and 2 side gear thrust washers.

REPLACEMENT





1. REPLACE SIDE GEAR SHAFT DUST COVER
a. Using a screwdriver and a hammer, remove the side gear shaft dust cover.
b. Using a steel plate and a press, install a new dust cover to the side gear shaft.

NOTICE: Be careful not to damage the dust cover.

2. REPLACE COMPANION FLANGE DUST DEFLECTOR





a. Using SST and a press, remove the dust deflector.
SST 09950-00020
b. Using a press, install a new dust deflector.

REASSEMBLY
1. 2 pinion differential:
REASSEMBLE DIFFERENTIAL CASE





a. Install the 2 proper thrust washers on the 2 side gears.
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.
1. Install the 2 side gear shafts.
2. 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.

HINT: Refer to the table and select 2 thrust washers which ensures that the backlash is within the specification.





Thrust washer thickness

3. Remove the 2 side gear shafts.





d. Using a pin punch and a hammer, install the straight pin through the differential case and hole of the pinion shaft.
e. Using a chisel and a hammer, stake the outside of the differential case pin hole.
2. 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 4 new lock plates and the 8 bolts.
g. After the ring gear cools down enough, torque the 8 bolts uniformly at a time.
Torque: 97 Nm (985 kgf-cm, 71 ft. lbs.)
h. Using a chisel and a hammer, raise up claws of the 4 lock plates.

HINT:
^ Bend one of the claws which touches the flat surface of the bolt so that the claw can contact the surface firmly.
^ If one of the claws is divided into two due the protruding portion of the bolt, make the claw contact firmly with the tightening side of the bolt.

3. INSTALL SIDE BEARINGS





Using SST and a press, install the 2 side bearings into the differential case.
SST 09710-22021 (09710-01031)





4. INSPECT RING GEAR RUNOUT
a. Install the differential case on the carrier, and install the 2 plate washers so that there 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.
5. INSTALL FRONT AND REAR BEARING OUTER RACES





a. Front side:
Using SST and a press, install the outer race to the carrier.
SST 09950-60020 (09951-00790), 09951-70010 (09951-07150)
b. Rear side:
Using SST and a press, install the 2 outer races to the carrier.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
6. INSTALL DRIVE PINION REAR BEARING
a. Install the removed plate washer on the drive pinion.





b. Using SST and a press, install the rear bearing onto the drive pinion.
SST 09506-30012
7. 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, install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03020)
c. Coat the threads of the nut with MP grease.





d. Adjusting the drive pinion preload by tightening the companion flange nut.
Using SST to hold the flange, tighten the nut.
Torque: 108 - 235 Nm (1,100 - 2,400 kgf-cm, 80 - 173 ft. lbs.)
SST 09330-00021

NOTICE: Without a spacer, torque a little at a time, being careful not to over tighten it.





e. Using a torque wrench, measure the preload.





Preload (at starting):





8. 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.
9. ADJUST RING GEAR BACKLASH
a. Install only the plate washer on the ring gear back side.
b. Make the washer and bearing fit by tapping the ring gear with a plastic hammer.





c. Using a dial indicator, hold the companion flange and measure the ring gear backlash.
Backlash (reference): 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
d. Select a ring gear back side plate washer so that the backlash becomes 0.13 - 0.18 mm (0.0051 - 0.0071 inch).





e. Select a ring gear teeth side washer so that there is no 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 on 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, make the washer fit and bearing by tapping the ring gear.





j. Using a dial indicator, measure the ring gear backlash during holding the companion flange.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
If the value 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 clearance between the plate washer and case. Ensure that there is the ring gear backlash.

10. ADJUST SIDE BEARING PRELOAD
a. After adjusting 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 of 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 a hammer, tap the plate washer.





e. Align the matchmarks on the cap and carrier, and install the 2 bearing caps with the 4 bolts.
Torque: 78 Nm (800 kgf-cm, 58 ft. lbs.)





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

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





Washer thickness:





11. MEASURE TOTAL PRELOAD
Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus 0.3 - 0.5 Nm (3 - 5 kgf-cm, 2.6 - 4.3 inch lbs.)
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.





Washer thickness:

13. REMOVE COMPANION FLANGE
14. REMOVE FRONT BEARING





15. INSTALL NEW BEARING SPACER AND FRONT BEARING
Install a new bearing spacer and the front bearing on the drive pinion.
16. INSTALL OIL SLINGER
17. INSTALL NEW FRONT OIL SEAL





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





a. Using SST, install the companion flange on the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09950-03010, 09955-03040, 09956-03020)
b. Coat the threads of a new nut with hypoid gear oil.





c. Using SST to hold the flange, torque the nut.
SST 09330-00021
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
19. CHECK DRIVE PINION PRELOAD





Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.





Preload (at starting):

If the preload is larger than the specification, replace the bearing spacer.
If the preload is less than the specification, retighten the nut 13 Nm (130 kgf-cm, 9 ft. lbs.) of torque at a time until reaching the specified value.
Torque: 235 Nm (2,400 kgf-cm, 174 ft. lbs.) or less
If the torque exceeds the maximum value while retighten the nut, replace the bearing spacer and repeat the preload procedure. Do not loosen the pinion nut to reduce the preload.
20. RECHECK TOTAL PRELOAD
21. RECHECK RING GEAR BACKLASH
22. RECHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
23. CHECK COMPANION FLANGE RUNOUT
24. STAKE DRIVE PINION NUT
25. INSTALL SIDE GEAR SHAFT OIL SEALS





a. Using SST and a hammer, install 2 oil seals until they are flush with the carrier end surface.
SST 09550-00032, 09950-70010 (09951-07150)
b. Coat the oil seal lip with MP grease.
26. Torque sensing LSD:
INSTALL SIDE GEAR SHAFTS
a. Install 2 new snap rings to the side gear shafts.





b. Using SST, install the 2 side gear shafts until they contacts the pinion shaft.
SST 09520-24010 (09520-04010, 09520-32040)

HINT: Check that the shaft is fully inserted by the noise being made when it is tapped.





27. 2 pinion differential:
INSTALL SIDE GEAR SHAFTS
a. Install the 2 side gear shafts to the differential case.
b. Using needle nose pliers, install 2 new snap rings to 2 side gear shafts.





28. INSTALL DIFFERENTIAL CARRIER COVER
a. Torque sensing LSD: Install the oil deflector and bolt to the carrier cover.
Torque: 7.3 Nm (75 kgf-cm, 65 inch lbs.)
b. Install the breather plug to the carrier cover.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
c. Clean contacting surfaces of any residual FIPG material by using gasoline or alcohol.
d. Apply FIPG to the carrier.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

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

e. Torque the 8 bolts.
Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.)