Part 1

AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY

REASSEMBLY

1. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Install the 2 rear No. 1 differential side gear thrust washers to the 2 differential side gears.
NOTICE:
- Make sure that there is no foreign matter on or cracks and chips in the rear No. 1 differential side gear thrust washers, differential side gears and differential pinion gears, before installation.
- When replacing a differential side gear or differential pinion gears, replace both sides as one set.
- Apply sufficient hypoid gear oil to any sliding or rotating parts.

(b) Install the 2 differential side gears, 2 differential pinion gears, 2 rear differential pinion thrust washers and rear differential pinion shaft in the differential case.
HINT: Align the holes of the differential case and rear differential pinion shaft.

(c) Measure the differential side gear backlash while holding a differential pinion gear toward the differential case.
Backlash:
0.05 to 0.20 mm (0.00197 to 0.00787 in.)
If the backlash is not within the specification, install the 2 rear No. 1 differential side gear thrust washers with different thicknesses.
HINT: Refer to the table below and select 2 rear No. 1 differential side gear thrust washers which ensure that the backlash is within the specification.

Rear No. 1 Differential Side Gear Thrust Wash

(d) Using a pin punch (3 mm) and a hammer, install the rear differential pinion shaft pin through the differential case and hole of the rear differential pinion shaft.
(e) Using a chisel and a hammer, stake the outside of the differential case pin hole.
2. INSTALL DIFFERENTIAL RING GEAR

(a) Clean the contact surfaces of the differential case and differential ring gear.

Text in Illustration

(b) Heat the differential ring gear in boiling water.
(c) Carefully remove the differential ring gear from the boiling water.
(d) After the moisture on the differential ring gear has completely evaporated, quickly install the differential ring gear to the differential case.

(e) Align the matchmarks on the rear differential case and differential ring gear, and install the differential ring gear.

Text in Illustration

(f) Temporarily install 10 new bolts.
(g) After the differential ring gear cools down sufficiently, tighten the 10 bolts uniformly at a time.
Torque: 78 Nm (795 kgf-cm, 58ft-lbf)
NOTICE:
- The new bolts are coated with heat resistant oil. Do not wash it off.
- Install the rear differential case bolts by tightening diametrically opposite bolts uniformly in several passes.
- Tighten the rear differential case bolts after the differential ring gear has cooled down sufficiently.

3. INSTALL REAR DIFFERENTIAL CASE BEARING

(a) Using SST and a press, install the rear differential case bearing (RH side inner race) to the rear differential case sub-assembly.
SST: 09223-46011
If the rear differential case bearing (RH side inner race) is damaged, replace it with a new one.
4. INSTALL REAR DIFFERENTIAL CASE BEARING

(a) Using SST and a press, install the rear differential case bearing (LH side inner race) to the rear differential case sub-assembly.
SST: 09223-46011
If the rear differential case bearing (LH side inner race) is damaged, replace it with a new one.
5. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, install the 4 straight pins to the differential carrier.

(A):
8 to 9 mm (0.315 to 0.354 in.)
(b) Thoroughly remove oil and water from the surface of the rear differential case sub-assembly that will face the differential ring gear.
6. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using SST, bolts, nuts and washers, install the rear drive pinion rear tapered roller bearing (outer race) to the rear differential carrier.
SST: 09950-60010
09951-00540
09951-00620
SST: 09950-60020
09951-00680
HINT: Use M12 x P1.25 bolts with shaft lengths of 186 mm (7.32 in.) (part No. 90101-12159) and M12 x P1.25 nuts (part No. 90179-12051) for installation.

7. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Using SST, bolts, nuts and washers, install the rear drive pinion front tapered roller bearing (outer race) to the rear differential carrier.
SST: 09950-60010
09951-00490
09951-00540
09951-00620
SST: 09950-60020
09951-00680
HINT: Use M12 x P1.25 bolts with shaft lengths of 186 mm (7.32 in.) (part No. 90101-12159) and M12 x P1.25 nuts (part No. 90179-12051) for installation.

8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Install the rear differential drive pinion plate washer to the differential drive pinion.
NOTICE: Install each rear differential drive pinion washer to the position it was removed from.

(b) Using SST and a press, install the rear drive pinion rear tapered roller bearing (inner race) to the differential drive pinion.
SST: 09316-60011
09316-00071
9. INSTALL REAR DIFFERENTIAL CASE BEARING

(a) Using SST and a press, install the rear differential side gear shaft plate washer and rear differential case bearing (RH side outer race) to the rear differential carrier.

Text in Illustration

(a) Using SST and a press, install the rear differential side gear shaft plate washer and rear differential case bearing (LH side outer race) to the differential side bearing retainer.

Text in Illustration

SST: 09950-60010
09951-00580
09952-06010
SST: 09950-60020
09951-00680
SST: 09950-70010
09951-07100

NOTICE:
- Install each rear differential side gear shaft plate washer to the position it was removed from.
- When replacing a rear differential case bearing, replace the inner and outer races as a set.
- Install the rear differential side gear shaft oil seal after performing the tooth contact inspection and backlash adjustment.

11. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Install the differential drive pinion with rear drive pinion rear tapered roller bearing (inner race) to the rear differential carrier.
(b) Install the rear drive pinion front tapered roller bearing (inner race) and a new rear drive pinion nut to the differential drive pinion.
NOTICE:
- New bearings are coated with anti-rust oil. If using new bearings, do not wash it off.
- If reusing a bearing, coat it with hypoid gear oil API GL-5.

(c) Using SST, gradually tighten the rear drive pinion nut until the specified preload is reached. Do not exceed the torque limit shown below.
SST: 09564-16020
without SST - Torque: 245 Nm (2498 kgf-cm, 181ft-lbf) or less
with SST - Torque: 223 Nm (2274 kgf-cm, 164ft-lbf) or less
NOTICE: Tighten the rear drive pinion nut gradually. Never tighten it excessively.
HINT: Use a torque wrench with a fulcrum length of 500 mm (1.64 ft.).

(d) Using SST and a torque wrench, measure the differential drive pinion preload (starting torque) of the differential drive pinion.
SST: 09556-16011
Standard drive pinion preload (New bearing):
0.7 to 1.3 N*m (7 to 13 kgf*cm, 6 to 11 in.*lbf)
Standard drive pinion preload (Reused bearing):
0.4 to 0.7 N*m (4 to 7 kgf*cm, 3 to 6 in.*lbf)

NOTICE:
- For a more accurate measurement, rotate the bearing forward and backward before inspection.
- Record the preload measurement for use with the total preload measurement.

12. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Using a scraper and wire brush, remove the seal packing from the rear differential carrier and differential side bearing retainer.
NOTICE: Do not scratch the installation surface.

(b) Install the rear differential case sub-assembly to the rear differential carrier.
(c) Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.
Torque: 42 Nm (428 kgf-cm, 31ft-lbf)
13. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Insert a dial indicator and magnetic base through the rear differential filler plug hole and set it perpendicular to a ring gear tooth surface's tip.
(b) Using SST, hold the drive pinion in place.
SST: 09556-16011

(c) Using SST, rotate the rear differential case forward and backward, and measure the backlash.
SST: 09564-32011
Backlash:
0.10 to 0.15 mm (0.00394 to 0.00591 in.)
NOTICE: Measure at 3 or more areas on the circumference of the ring gear.

(d) If the result is not within the specified range, select rear differential side gear shaft plate washers that are thicker or thinner as necessary. Adjust the thickness of the left and right rear differential side gear shaft plate washers in equal increments. Then install the rear differential case bearing (outer race).
HINT:
- When the backlash is smaller than the specified value, select a thick rear differential side gear shaft plate washer for the RH side and thin rear differential side gear shaft plate washer for the LH side.
- When the backlash is larger than the specified value, select a thin rear differential side gear shaft plate washer for the RH side and thick rear differential side gear shaft plate washer for the LH side.

Rear Differential Side Gear Shaft Plate Washer

14. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Remove the 10 bolts and the differential side bearing retainer.
(b) Remove the differential case sub-assembly from the rear differential carrier.
(c) Coat 3 or 4 teeth at 4 different positions on the differential ring gear with Prussian blue.
(d) Install the differential case sub-assembly to the rear differential carrier.
(e) Install the differential side bearing retainer with the 10 bolts.
Torque: 42 Nm (428 kgf-cm, 31ft-lbf)
(f) Turn the differential drive pinion several times.
(g) Remove the 10 bolts and the differential side bearing retainer.
(h) Inspect the tooth contact pattern.
NOTICE: Check the tooth contact pattern at 2 or more positions on the circumference of the differential ring gear.

(i) Perform the following procedure for face or flank contact:
(1) If the result is not within the specified range, select rear differential side gear shaft plate washers that are thicker or thinner as necessary. Adjust the thickness of the left and right rear differential side gear shaft plate washers in equal increments. Then install the rear differential case bearing (outer race).
(2) Repeat the differential ring gear and differential drive pinion tooth contact pattern inspection.
HINT: If the tooth contact pattern is not correct, reselect rear differential side gear shaft plate washers and reinspect the tooth contact pattern.
(3) Repeat the differential ring gear and differential drive pinion backlash inspection.
HINT: If the differential ring gear and differential drive pinion backlash are not as specified, replace the differential ring gear and differential drive pinion with new ones.

(j) Perform the following procedure for heel or toe contact:

(1) Select a rear differential drive pinion plate washer again and install the rear drive pinion rear tapered roller bearing (inner race).

Text in Illustration

Rear Differential Drive Pinion Plate Washer

15. MEASURE TOTAL PRELOAD

(a) Using SST and a torque wrench, measure the total preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.
SST: 09556-16011
Standard total preload (New bearing):
Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)
Standard total preload (Reused bearing):
Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)
HINT: For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

(b) If the results are not within the specification, perform the procedure below:
(1) Select a thicker or thinner rear differential side gear shaft plate washer for the RH side, and then install the rear differential case bearing outer race (RH side only).
(2) Repeat the total preload measurement.
(3) Repeat the differential ring gear backlash inspection.
(4) Repeat the differential ring gear and drive pinion tooth contact pattern inspection.
16. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Remove the rear differential case sub-assembly from the rear differential carrier.
17. REMOVE DIFFERENTIAL DRIVE PINION
(a) Remove the differential drive pinion from the rear differential carrier.
18. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Install a new rear differential drive pinion bearing spacer to the differential drive pinion.
NOTICE: Face the smaller inside diameter towards the front of the vehicle.

19. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Install the rear differential drive pinion oil slinger to the differential drive pinion.
20. INSTALL DIFFERENTIAL DRIVE PINION

(a) Install the differential drive pinion and rear drive pinion front tapered roller bearing (inner race) to the differential carrier.
21. INSTALL REAR DRIVE PINION NUT
(a) Apply hypoid gear oil LSD to the threads of a new rear drive pinion nut.

(b) Install the new rear drive pinion nut to the differential drive pinion. Using SST, tighten the new rear drive pinion nut while confirming the preload.
SST: 09564-16020
without SST - Torque: 245 Nm (2498 kgf-cm, 181ft-lbf) or less
with SST - Torque: 223 Nm (2274 kgf-cm, 164ft-lbf) or less
HINT: Use a torque wrench with a fulcrum length of 500 mm (1.64 ft.).