Part 2

Overhaul continued





61. INSTALL FRONT DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the 2 differential case bearings into the differential case assembly.
SST 09226-10010
62. INSTALL SIDE BEARING OUTER RACE

HINT: When replacing the 2 differential case bearings, fit 2 of the thinnest new washers to each bearing and when reusing the bearings, fit washers of the same thickness as those removed.

a. Install a new plate washer to the side bearing retainer.





b. Using SST and a press, install the bearing outer race onto the differential case bearing retainer assembly.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07150)
c. Install a new plate washer onto the differential carrier assembly.





d. Using SST and a press, install the bearing outer race onto the differential carrier assembly.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07150)





63. INSTALL FRONT BEARING OUTER RACE
a. Using SST, install the outer race.
SST 09950-00020 (09951-00680, 09951-00890)
64. INSTALL REAR BEARING OUTER RACE
a. Install the oil storage ring.
b. Using SST, install the outer race.
SST 09950-00020 (09951-00680, 09951-00890)
65. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Install the washer onto the drive pinion.

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





b. Using SST and a press, install the front bearing onto the drive pinion.
SST 09506-30012
66. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Install the drive pinion.

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





b. Using SST, install the rear bearing, oil slinger and companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
c. Coat the threads of the nut with hypoid gear oil.





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

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 preload of the back lash between the drive pinion and ring gear.
Preload (at starting)
New bearing: 0.98 to 1.57 Nm (10 to 16 kgf-cm, 8.7 to 13.9 inch lbs.)
Reused bearing: 0.49 to 0.78 Nm (5 to 8 kgf-cm, 4.3 to 6.9 inch lbs.)
If necessary, disassemble and inspect the differential assy.
67. INSTALL DIFFERENTIAL CASE ASSY
68. ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION
a. Install the side bearing retainer with the 10 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)





b. Using SST and a dial indicator, measure the ring gear backlash.
SST 09564-32011
Backlash: 0.11 to 0.21 mm (0.0043 to 0.0083 inch)
c. If it is not within the specification, adjust it by either in creasing or decreasing the thickness of the washers on both sides by an equal amount.

HINT: There should be no clearance between the plate washer and differential case. Make sure that there is ring gear backlash.





Washer thickness





69. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus 0.22 to 0.88 Nm (2.2 to 8.8 kgf-cm, 2.0 to 7.8 inch lbs.)
If necessary, disassemble and inspect the differential.
70. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Remove the side bearing retainer and differential case assembly.





b. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead.
c. Install the differential case assembly and side bearing retainer.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
d. Hold the companion flange firmly and rotate the ring gear in both directions.
e. Remove the differential case, side bearing retainer and differential case assembly.





f. Inspect the tooth contact pattern.





If the teeth are not engaged properly, use the chart to select the appropriate washer for correction.





Washer thickness





g. Using SST to hold the companion flange, remove the nut.
SST 09330-00021





h. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020),





i. Using SST, remove the rear bearing from the drive pinion.
SST 09556-22010
71. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install a new bearing spacer and oil storage ring.
72. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
73. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
74. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSY FRONT
a. Place the companion flange on the drive pinion.
b. Coat the threads of a new nut with hypoid gear oil LSD.





c. Using SST and the companion flange, install the rear tapered roller bearing, then remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)





75. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL
a. Using SST and a hammer, install the oil seal.
SST 09554-22010
Oil seal drive in depth: 4.35 - 0.45 mm (0.171 - 0.018 inch)
b. Coat the oil seal lip with MP grease.





c. Using SST to hold the flange, tighten the nut.
Torque: 370 Nm (3,773 kgf-cm, 273 ft. lbs.)
SST 09330-00021





76. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and side bearing retainer.
b. Clean the contact surfaces of any residual FIPG material using gasoline or alcohol.
c. Apply FIPG to the side bearing retainer, as shown.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent

HINT: Install the side bearing retainer within 10 minutes of applying FIPG.

d. Install the side bearing retainer with the 10 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
e. Install the union.





77. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the back lash between the drive pinion and ring gear.
Preload (at starting)
New bearing: 0.98 to 1.57 Nm (10 to 16 kgf-cm, 8.7 to 13.9 inch lbs.)
Reused bearing: 0.49 to 0.78 Nm (5 to 8 kgf-cm, 4.3 to 6.9 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 to 13 Nm (130 kgf-cm, 9 ft. lbs.) a little at a time until the specified preload is reached.
Torque: 370 Nm (3,773 kgf-cm, 273 ft. lbs.) or less
If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repair the preload procedure.
Do not loosen the nut to reduce the preload.
78. INSPECT TOTAL PRELOAD (See step 69)
79. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION (See step 68)





80. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSY FRONT
a. Using a dial indicator, measure the runout of the drive pinion companion flange vertically and horizontally.
Maximum runout:
Vertical runout: 0.10 mm (0.0039 inch)
Lateral runout: 0.10 mm (0.0039 inch)
If the runouts are not within the specifications, replace the companion flange.





81. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
a. Using a chisel and hammer, stake the drive pinion nut.





82. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST and a plastic hammer, install a new oil seal until its surface is flush with the differential carrier end.
SST 09608-32010
b. Coat the oil seal lip with MP grease.
Oil seal driven in depth: 0 - 0.45 mm (0 - 0.0177 inch)





83. INSTALL DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSY
a. Install a new snap ring onto the side gear inter shaft.
b. Using a plastic hammer, install the side gear inter shaft onto the differential case.
c. Check that there are 2 to 3 mm (0.08 to 0.12 inch) of play in the axial direction.
d. Check that the side gear inter shaft will not come out by trying to pull it completely out by hand.





84. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR
a. Using a brass bar and a hammer, install the side bearing retainer deflector.

NOTICE: Be sure to install the side bearing retainer deflector in the correct direction.





85. INSTALL FRONT DIFFERENTIAL TUBE ASSY
a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential and clutch case.
b. Clean the contact surfaces of any residual FIPG material using gasoline or alcohol.
c. Apply FIPG to the differential, as shown.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent

HINT: Install the differential tube within 10 minutes of applying FIPG.

d. Install the differential tube into the differential carrier assembly.





e. Clean the threads of the 4 bolts and retainer bolt holes with toluen or trichloroethylene.
f. Apply adhesive to 2 to 3 threads of each bolt end.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent
g. Install the 4 bolts.
Torque: 110 Nm (1,122 kgf-cm, 81 ft. lbs.) or less





86. INSTALL DIFFERENTIAL VACUUM ACTUATOR ASSY
a. Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the actuator and clutch case.
b. Clean the contact surfaces of any residual FIPG material using gasoline or alcohol.
c. Apply FIPG to the differential tube, as shown.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent

HINT: Install the actuator within 10 minutes of applying FIPG.





d. Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
e. Install the actuator assy onto the differential tube.
f. Apply adhesive to 2 to 3 threads of each bolt end.
Adhesive: Part No.08833-00070, THREE BOND 1281 or equivalent
g. Install the 4 bolts.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)





87. INSTALL DIFFERENTIAL CARRIER ASSY FRONT
a. Connect the actuator hose and connector.
b. Install the No.1 mounting support with the 3 bolts.
Torque: 186 Nm (1,899 kgf-cm, 138 ft. lbs.)
c. Install the No.2 mounting support with the 2 bolts.
Torque: 160 Nm (1,631 kgf-cm, 118 ft. lbs.)
d. Install the front differential support No.3 with the 2 bolts.
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
e. Support the front differential with a jack.
f. Install the 2 front mounting bolts and nuts.
Torque: 137 Nm (1,400 kgf-cm, 101 ft. lbs.)
g. Install the front differential mount nut No.1.
Torque: 87 Nm (889 kgf-cm, 64 ft. lbs.)
h. Install the front differential breather tube bracket with the bolt.
Torque: 13 Nm (129 kgf-cm, 8 ft. lbs.)
i. Lower the jack.
88. INSTALL FRONT DRIVE SHAFT ASSY LH
89. INSTALL FRONT DRIVE SHAFT ASSY RH
90. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
91. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
92. INSTALL TIE ROD END SUB-ASSY LH
93. INSTALL TIE ROD END SUB-ASSY RH
94. INSTALL SPEED SENSOR FRONT LH
95. INSTALL SPEED SENSOR FRONT RH
96. INSTALL FRONT STABILIZER LINK ASSY LH
97. INSTALL FRONT STABILIZER LINK ASSY RH
98. INSTALL FRONT AXLE HUB LH NUT
99. INSTALL FRONT AXLE HUB RH NUT
100. INSTALL PROPELLER SHAFT ASSY FRONT
101. ADD DIFFERENTIAL OIL
102. INSPECT DIFFERENTIAL OIL
103. INSPECT FOR DIFFERENTIAL OIL LEAKAGE
104. INSTALL ENGINE UNDER COVER SUB-ASSY NO.2 (W/ ENGINE UNDER COVER NO.2)
a. Install the engine under cover sub-assembly No.2 with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
105. INSTALL ENGINE UNDER COVER SUB-ASSY NO.1
a. Install the engine under cover assembly No.1 with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
106. INSTALL FRONT WHEEL
Torque: 113 Nm (1,152 kgf-cm, 83 ft. lbs.)
107. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
108. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
109. CHECK ABS SENSOR SIGNAL (W/ VSC)
110. CHECK ABS SENSOR SIGNAL (W/O VSC)