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# REAR DIFFERENTIAL CARRIER ASSEMBLY > REASSEMBLY

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1. ASSEMBLE DIFFERENTIAL CASE (for 2 Pinion Gear Type)

1. Install the side gear thrust washer to the side gear.

   HINT:
     Using the table below, select 2 thrust washers which will ensure that the backlash is within the specifications.

   Washer thickness:

     Thickness mm (in.) | Thickness mm (in.)
     1.48 to 1.52 (0.058 to 0.060) | 1.73 to 1.77 (0.068 to 0.070)
     1.53 to 1.57 (0.060 to 0.062) | 1.78 to 1.82 (0.070 to 0.072)
     1.58 to 1.62 (0.062 to 0.064) | 1.83 to 1.87 (0.072 to 0.074)
     1.63 to 1.67 (0.064 to 0.066) | 1.88 to1. 92 (0.074 to 0.076)
     1.68 to 1.72 (0.066 to 0.068) | -

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

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

1. Measure the side gear backlash.

   1. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.

      Backlash:
        0.05 to 0.20 mm (0.002 to 0.008 in.)
      1. If the backlash is not as specified, install 2 side gear thrust washers with different thicknesses.

1. Using a pin punch and hammer, tap in the straight pin through the differential case and hole of the pinion shaft.

1. Stake the differential case.

2. ASSEMBLE DIFFERENTIAL CASE (for LSD)

1. Measure the differential case dimension labeled A.

1. Install the side gear thrust washers No. 1 and clutch plate to the side gear.

1. While using SST to press the washers and plates with a pressure of 10 kgf (22 lbf), measure the dimension B.

1. Calculate the thickness of the new washer using the formula below.

   Selected thrust washer = A - B - 16.175 mm (0.6368 in.):

     Thickness mm (in.) | Identifying Mark
     1.83 to 1.89 (0.072 to 0.074) | B
     1.89 to 1.95 (0.074 to 0.077) | C
     1.95 to 2.01 (0.077 to 0.079) | D
     2.01 to 2.07 (0.079 to 0.081) | E
     2.07 to 2.13 (0.081 to 0.084) | F
     2.13 to 2.19 (0.084 to 0.086) | G
     2.19 to 2.25 (0.086 to 0.089) | H
     2.25 to 2.31 (0.089 to 0.091) | J
     2.31 to 2.37 (0.091 to 0.093) | K
     2.37 to 2.43 (0.093 to 0.096) | L

1. Install the following parts to the differential cases.

   1. (1) Side gear thrust washer
   2. (2) Clutch plate
   3. (3) No. 1 side gear thrust washer
   4. (4) Side gear

1. Install the 4 pinion gears and thrust washers to the spider.

1. Align the spring RH retainer holes with the spider knock pins and install the RH retainer.

1. Install the pinion gears and spider to the differential RH case.

   HINT:
     Install the spider to the RH case tightly and do not move the spring retainer.

1. Using a dial indicator, measure the side gear backlash while holding the side gear spider.

   Backlash:
     0.05 to 0.20 mm (0.0020 to 0.0079 in.)
   1. If the backlash is not within the specification, install an adjusting shim of a different thickness.

      HINT:
      1. Measure at all 4 locations.
      1. Measure the backlash at the LH case and at the RH case.

1. Reinstall the spider to the RH case tightly and do not move the spring retainer.

1. Install the compression spring and spring LH retainer.

1. Install the side gear, thrust washers and clutch plates.

1. Align the matchmarks and assemble the RH and LH cases.

   HINT:
     Be careful not to drop the side gear and check the pinion and side gear alignment.

1. Align the matchmarks on the differential case RH and differential case LH.

1. Install the 8 bolts by diametrically tightening the bolts uniformly in several passes.

   Torque:
     47 N*m{ 480 kgf*cm , 35 ft.*lbf }

3. INSTALL DIFFERENTIAL RING GEAR

1. Clean the contact surfaces of the differential case and ring gear.

1. Heat the ring gear in boiling water that is approximately 100°C (212°F).

1. Carefully remove the ring gear from the boiling water.

1. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

1. Align the matchmarks on the ring gear with those of the differential case.

1. Temporarily install 5 new lock plates and 10 bolts.

1. After the ring gear cools down, install the 8 bolts by diametrically tightening the bolts uniformly in several passes.

   Torque:
     84 N*m{ 857 kgf*cm , 62 ft.*lbf }

1. Using a chisel and hammer, stake the 5 lock plates.

   HINT:
     Strike the tab labeled A so that it is flush with the flat surface of the bolt. Strike the tab labeled B so that half of the tab contacts the bolt as shown in the illustration.

4. INSTALL REAR DIFFERENTIAL CASE BEARING

1. Using SST and a press, press the bearing onto the differential case.

   SST
     09950-60010 (09951-00430, 09951-00480, 09951-00470, 09951-00550)
     09950-70010 (09951-07150, 09951-00560, 09951-00570)

5. INSPECT DIFFERENTIAL RING GEAR RUNOUT

1. Install the differential case on the carrier, and install the 2 adjusting nuts so that there is no play in the bearing.

1. Install the 2 bearing caps with the 4 bolts.

   Torque:
     85 N*m{ 870 kgf*cm , 63 ft.*lbf }

1. Using a dial indicator, measure the runout of the ring gear.

   Maximum runout:
     0.07 mm (0.0028 in.)

1. Remove the 2 bearing caps, 2 adjusting nuts and differential case.

6. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

1. Using SST, a plate and a press, press in the dust deflector.

   SST
     09636-20010

   NOTICE:
     Be careful not to damage the dust deflector.

7. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

1. Using a brass bar and hammer, tap in the oil storage ring.

1. Using SST and a press, press the roller bearing (outer) to the carrier.

   SST
     09316-60011 (09316-00011, 09316-00021)

8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

1. Using SST and a press, press the roller bearing (outer) into the carrier.

   SST
     09316-60011 (09316-00041, 09316-00011)

9. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

1. Install the plate washer on the drive pinion.

   HINT:
     First fit a washer with the same thickness as the removed washer, and then check the tooth contact pattern. Replace the washer with one of a different thickness if necessary.

1. Using SST and a press, press the roller bearing (inner) onto the drive pinion.

   SST
     09506-30012

10. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

1. Install the drive pinion, rear drive pinion tapered roller bearing and rear differential drive oil slinger.

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

1. Using SST, install the companion flange.

   SST
     09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)
     09330-00021 (09330-00030)

   NOTICE:
     Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

1. Adjust the drive pinion preload by tightening the companion flange nut.

1. Using SST to hold the companion flange in place, torque the nut.

   SST
     09330-00021 (09330-00030)

   Torque:
     370 N*m{ 3,770 kgf*cm , 273 ft.*lbf }

   NOTICE:
   1. As there is no spacer, torque a little at a time. Be careful not to overtighten the nut.
   1. Apply hypoid gear oil LSD to the nut.

1. Using a torque wrench, measure the preload.

   Preload (at start of torque):

     Bearing | Preload
     New bearing | 1.05 to 1.64 N*m (10.7 to 16.7 kgf*cm, 9.3 to 14.5 in.*lbf)
     Reused bearing | 0.56 to 0.85 N*m (5.7 to 8.7 kgf*cm, 4.9 to 7.5 in.*lbf)

   NOTICE:
     For a more accurate measurement, rotate the bearing forward and backward several times before measuring.

11. INSTALL DIFFERENTIAL CASE ASSEMBLY

1. Place the 2 bearing outer races on their respective bearings.

   HINT:
     Make sure the right and left races are not interchanged.

12. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT

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

13. INSPECT AND ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION

1. Align the matchmarks on the cap and carrier.

1. Install the right and left bearing caps with the 4 bolts.

   Torque:
     85 N*m{ 870 kgf*cm , 63 ft.*lbf }
   1. If the bearing cap does not fit tightly on the carrier, the adjusting nuts are not threaded properly.

      HINT:
        Reinstall the adjusting nuts if necessary.

1. Loosen the 4 bearing cap bolts to the point where the adjusting nuts can be turned by SST.

1. Using SST, torque the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008 in.).

   SST
     09504-00011
     09960-10010 (09962-01000, 09963-00700)

1. While turning the ring gear, use SST to fully tighten the adjusting nut on the drive pinion side. After the bearings have settled, loosen the adjusting nut on the drive pinion side.

1. Using SST, tighten the adjusting nut 1 to 1.5 notches from the 0 preload position.

   SST
     09504-00011
     09960-10010 (09962-01000, 09963-00700)

1. Using a dial indicator, adjust the ring gear backlash until it is within the specification.

   Backlash:
     0.13 to 0.18 mm (0.0051 to 0.0071 in.)

   HINT:
   1. The backlash is adjusted by turning the left and right adjusting nuts an equal amount. For example, loosen the nut on the right side one notch and loosen the nut on the left side one notch.
   1. Perform the measurement at 3 or more positions around the circumference of the ring gear.

1. Torque the bearing cap bolts.

   Torque:
     85 N*m{ 870 kgf*cm , 63 ft.*lbf }

14. INSPECT TOTAL PRELOAD

1. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

   Torque:
     Total preload (at start of torque):
     0.39 to 0.59 N*m{ 4 to 6 kgf*cm , 3.4 to 5.2 ft.*lbf } + drive pinion preload
   1. If necessary, disassemble and inspect the differential.

15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

1. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.

1. Hold the companion flange firmly in place and rotate the ring gear in both directions.

1. Inspect the tooth contact pattern.

   3. If the teeth are not contacting properly, use the following chart to select a proper washer.

      Plate washer thickness:

        Thickness mm (in.) | Thickness mm (in.)
        1.69 to 1.71 (0.0665 to 0.0673) | 2.02 to 2.04 (0.0795 to 0.0803)
        1.72 to 1.74 (0.0677 to 0.0685) | 2.05 to 2.07 (0.0807 to 0.0815)
        1.75 to 1.77 (0.0689 to 0.0697) | 2.08 to 2.10 (0.0819 to 0.0827)
        1.78 to 1.80 (0.0701 to 0.0709) | 2.11 to 2.13 (0.0831 to 0.0839)
        1.81 to 1.83 (0.0713 to 0.0720) | 2.14 to 2.16(0.0843 to 0.0850)
        1.84 to 1.86 (0.0724 to 0.0732) | 2.17 to 2.19 (0.0854 to 0.0862)
        1.87 to 1.89 (0.0736 to 0.0744) | 2.20to 2.22 (0.0866 to 0.0874)
        1.90 to 1.92 (0.0748 to 0.0756) | 2.23 to 2.25 (0.0878 to 0.0886)
        1.93 to 1.95 (0.0760 to 0.0768) | 2.26 to 2.28 (0.0890 to 0.0898)
        1.96 to 1.98 (0.0772 to 0.0780) | 2.29 to 2.31 (0.0902 to 0.0909)
        1.99 to 2.01 (0.0783 to 0.0791) | 2.32 to 2.34 (0.0913 to 0.0921)

16. REMOVE REAR DRIVE PINION NUT

1. Using SST and a hammer, loosen the staked part of the nut.

   SST
     09930-00010 (09931-00010, 09931-00020)

1. Using SST to hold the companion flange in place, remove the nut.

   SST
     09330-00021 (09330-00030)

17. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

18. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

19. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

1. Using SST, remove the roller bearing (outer) from the carrier.

   SST
     09308-00010

1. Using a brass bar and hammer, tap out the oil storage ring from the carrier.

   HINT:
     If the bearing is damaged during removal, replace it.

20. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

1. Install a new bearing spacer to the drive pinion.

21. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

22. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

23. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

1. Apply MP grease to a new oil seal.

1. Using SST and a hammer, tap in the oil seal.

   SST
     09554-30011

   Oil seal depth:
     1.0 +- 0.45 mm (0.039 +- 0.0177 in.)

24. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

1. Using SST, install the companion flange on the drive pinion.

   SST
     09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)
     09330-00021 (09330-00030)

   NOTICE:
     Before using (center bolt), apply hypoid gear oil to its threads and tip.

1. Coat the threads of a new nut with hypoid gear oil LSD.

1. Using SST to hold the flange, torque the nut.

   SST
     09330-00021 (09330-00030)

   Torque:
     370 N*m{ 3,770 kgf*cm , 273 ft.*lbf } or less

25. INSPECT DRIVE PINION PRELOAD

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

   Preload (at start of torque):

     Bearing | Preload
     New bearing | 1.05 to 1.64 N*m (11 to 17 kgf*cm, 9.3 to 15 in.*lbf)
     Reused bearing | 0.56 to 0.85 N*m (6 to 9 kgf*cm, 4.9 to 7.5 in.*lbf)

   1. If the preload is greater than the maximum, replace the bearing spacer.
   1. If the preload is less than the minimum, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached.

   Torque:
     370 N*m{ 3,770 kgf*cm , 273 ft.*lbf } or less
   1. If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure.

   HINT:
     Do not loosen the pinion nut to reduce the preload.

26. INSPECT TOTAL PRELOAD

1. Using a torque wrench, measure the preload.

   Torque:
     Total preload (at start of torque):
     0.39 to 0.59 N*m{ 4 to 6 kgf*cm , 3.4 to 5.2 in.*lbf } + drive pinion preload
   1. If necessary, disassemble and inspect the differential.

27. INSPECT DIFFERENTIAL RING GEAR BACKLASH

1. Using a dial indicator, check the backlash of the ring gear.

   Backlash:
     0.13 to 0.18 mm (0.0051 to 0.0071 in.)
   1. If the backlash is not as specified, adjust the side bearing preload or repair as necessary.

      HINT:
        Perform the measurements at 3 or more positions around the circumference of the ring gear.

28. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

1. Using a dial indicator, measure the runout of the drive pinion companion flange vertically and laterally.

   Maximum runout:

     Runout | Maximum
     Vertical runout | 0.10 mm (0.0039 in.)
     Lateral runout | 0.10 mm (0.0039 in.)

   1. If the runout is greater than the maximum, replace the companion flange.

29. STAKE DRIVE PINION NUT

1. Using a chisel and hammer, stake the nut.

30. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK

1. Install 2 new adjusting locks on the bearing caps with the 2 bolts.

   Torque:
     13 N*m{ 130 kgf*cm , 96 ft.*lbf }

1. Bend the nut locks.

   HINT:
     Perform the measurements at 3 or more positions around the circumference of the ring gear.