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# FRONT DIFFERENTIAL CARRIER ASSEMBLY > REASSEMBLY

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1. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING

1. Using SST and a press, press in a new shaft bearing.

   SST
     09223-00010

1. Using a snap ring expander, install the snap ring.

   HINT:
     Install the snap ring securely.

2. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH

1. Install the shaft into the differential tube.

1. Using needle nose pliers, install the snap ring.

   HINT:
     Install the snap ring securely.

3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

1. Coat the lip of the new oil seal with MP grease.

   Oil seal depth:
     5.3 +- 0.5 mm (0.209 +- 0.020 in.)

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

   SST
     09223-15020

4. INSTALL DIFFERENTIAL CLUTCH HUB

1. Install the clutch hub to the side gear inter shaft.

1. Using snap ring pliers, install the snap ring.

   HINT:
     Install the snap ring securely.

   NOTICE:
     Make sure to install the differential clutch hub in the correct direction.

5. INSTALL FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING

1. Using SST and a press, press in 2 new bearings.

   SST
     09950-60010 (09951-00380)

   Needle roller bearing depth:
     1.7 mm +- 0.3 mm (0.067 +- 0.012 in.)

6. ASSEMBLE DIFFERENTIAL CASE

1. Install 2 thrust washers on the 2 side gears.

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

   Thrust washer thickness:

     Thickness mm (in.) | Thickness mm (in.)
     1.48 to 1.52 (0.0583 to 0.0598) | 1.73 to 1.77 (0.0681 to 0.0697)
     1.53 to 1.57 (0.0602 to 0.0618) | 1.78 to 1.82 (0.0701 to 0.0717)
     1.58 to 1.62 (0.0622 to 0.0638) | 1.83 to 1.87 (0.0720 to 0.0736)
     1.63 to 1.67 (0.0642 to 0.0657) | 1.88 to 1.92 (0.0740 to 0.0756)
     1.68 to 1.72 (0.0661 to 0.0677) | -

1. Install the 2 side gears, 2 pinion gears, 2 side gear thrust washers, 2 pinion thrust washers and 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:
        0.15 mm (0.0059 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.

7. INSTALL DIFFERENTIAL RING GEAR

1. Clean the contact surface 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. After the ring gear cools down, apply thread lock adhesive to the 10 set bolts and install them.

   Thread lock:
     Part No. 08833-00100, THREE BOND 1360k or equivalent.

   Torque:
     97 N*m{ 985 kgf*cm , 71 ft.*lbf }

8. INSTALL FRONT DIFFERENTIAL CASE BEARING

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

   SST
     09950-60010 (09951-00520, 09951-00610)
     09950-70010 (09951-07150)

9. INSTALL FRONT DIFFERENTIAL CASE BEARING

HINT:

  When replacing the 3 differential case bearings, fit the 2 thinnest new washers to each bearing. When reusing the bearings, fit the new washers to the same place they were removed from.

1. Using SST and a press, press in the case bearing (outer race) to the differential case bearing retainer.

   SST
     09950-60020 (09951-00810)
     09950-70010 (09951-07150)

1. Using SST and a press, press in the case bearing (outer) to the differential carrier.

   SST
     09950-60020 (09951-00810)
     09950-70010 (09951-07150)

10. INSTALL BEARING OUTER RACE

1. Using SST, install the outer race front.

   SST
     09950-00020 (09951-00890, 09951-00680)

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

1. Using SST, install the outer race rear.

   SST
     09950-00020 (09951-00890, 09951-00680)

11. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING

1. Install the washer on the drive pinion.

   HINT:
     First fit a washer that has the same thickness as the removed washer. After checking the tooth contact pattern, replace the washer with one of a different thickness if necessary.

1. Using SST and a press, press the front bearing onto the drive pinion.

   SST
     09506-30012

12. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

1. Install the drive pinion and 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, 09956-03020)
     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 flange in place, tighten the nut.

   SST
     09330-00021 (09330-00030)

   Torque:
     370 N*m{ 3,774 kgf*cm , 273 ft.*lbf } or less

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

1. Using a torque wrench, measure the preload.

   Preload (at start of torque):

     Item | Specified Condition
     New bearing | 0.98 to 1.57 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf)
     Reused bearing | 0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf)

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

13. INSTALL DIFFERENTIAL CASE ASSEMBLY

14. ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION

1. Install the side bearing retainer with the 10 bolts.

   Torque:
     50 N*m{ 510 kgf*cm , 37 ft.*lbf }

1. 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 in.)
   1. If the backlash is not as specified, adjust it by either increasing or decreasing the number of washers on both sides equally.

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

      Washer thickness:

        Thickness mm (in.) | Thickness mm (in.) | Thickness mm (in.)
        1.57 to 1.59 (0.0618 to 0.0626) | 1.75 to 1.77 (0.0689 to 0.0697) | 2.03 to 2.05 (0.0791 to 0.0807)
        1.59 to 1.61 (0.0626 to 0.0634) | 1.77 to 1.79 (0.0697 to 0.0705) | 2.05 to 2.07 (0.0807 to 0.0815)
        1.61 to 1.63 (0.0634 to 0.0642) | 1.79 to 1.81 (0.0705 to 0.0713) | 2.07 to 2.09 (0.0815 to 0.0822)
        1.63 to 1.65 (0.0642 to 0.0650) | 1.81 to 1.83 (0.0713 to 0.0720) | 2.09 to 2.11 (0.0822 to 0.0830)
        1.65 to 1.67 (0.0650 to 0.0657) | 1.83 to 1.85 (0.0720 to 0.0728) | 2.11 to 2.13 (0.0830 to 0.0839)
        1.67 to 1.69 (0.0657 to 0.0665) | 1.85 to 1.87 (0.0728 to 0.0736) | 2.13 to 2.15 (0.0839 to 0.0846)
        1.69 to 1.71 (0.0665 to 0.0673) | 1.87 to 1.89 (0.0736 to 0.0744) | 2.15 to 2.17 (0.0846 to 0.0854)
        1.71 to 1.73 (0.0673 to 0.0681) | 1.89 to 2.01 (0.0744 to 0.0791) | -
        1.73 to 1.75 (0.0681 to 0.0689) | 2.01 to 2.03 (0.0791 to 0.0799) | -

15. 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):
     0.22 to 0.88 N*m{ 2 to 9 kgf*cm , 1.9 to 7.7 in.*lbf } + drive pinion preload
   1. If necessary, disassemble and inspect the differential.

16. ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

1. Remove the differential case bearing retainer and differential case.

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

1. Install the differential case and differential case bearing retainer.

   Torque:
     50 N*m{ 510 kgf*cm , 37 ft.*lbf }

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

1. Remove the differential case bearing retainer and differential case.

1. Inspect the tooth contact pattern.

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

   Washer thickness:

     Thickness mm (in.) | Thickness mm (in.) | Thickness mm (in.)
     1.69 to 1,71 (0.0665 to 0.0673) | 1.93 to 1,95 (0.0760 to 0.0768) | 2.17 to 2.19 (0.0854 to 0.0862)
     1.72 to 1,74 (0.0677 to 0.0685) | 1.96 to 1,98 (0.0772 to 0.0780) | 2.20 to 2.22 (0.0866 to 0.0874)
     1.75 to 1,77 (0.0689 to 0.0697) | 1.99 to 2.01 (0.0783 to 0.0791) | 2.23 to 2.25 (0.0878 to 0.0886)
     1.78 to 1,80 (0.0700 to 0.0709) | 2.02 to 2.04 (0.0795 to 0.0803) | 2.26 to 2.28 (0.0890 to 0.0898)
     1.81 to 1,83 (0.0713 to 0.0720) | 2.05 to 2.07 (0.0807 to 0.0815) | 2.29 to 2.31 (0.0902 to 0.0909)
     1.84 to 1,86 (0.0724 to 0.0732) | 2.08 to 2.10 (0.0819 to 0.0827) | 2.32 to 2.34 (0.0913 to 0.0921)
     1.87 to 1,89 (0.0736 to 0.0744) | 2.11 to 2.13 (0.0831 to 0.0839) | -
     1.90 to 1,92 (0.0748 to 0.0756) | 2.14 to 2.16 (0.0843 to 0.0850) | -

17. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT

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

   SST
     09330-00021

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

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

18. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

1. Using SST, remove the companion flange.

   SST
     09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

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

19. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

20. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

1. Using SST, remove the roller bearing (inner) from the drive pinion.

   SST
     09556-22010

1. Remove the bearing spacer.

21. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

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

22. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

23. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

24. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL

1. Apply MP grease to the lip of a new oil seal.

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

   SST
     09554-22010

   Oil seal depth:
     4.35 +- 0.45 mm (0.1713 +- 0.0177 in.)

25. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR

1. Using a steel plate and a press, press in a new dust deflector.

   NOTICE:
     Do not damage the dust deflector.

26. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

1. Place the companion flange on the drive pinion.

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

1. Using SST, install the companion flange.

   SST
     09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

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

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 } or less

27. INSTALL DIFFERENTIAL SIDE BEARING RETAINER

1. Remove any old FIPG material from the side bearing retainer.

   NOTICE:
     Do not drop oil on the contact surfaces of the differential carrier and side bearing retainer.

1. Clean residual FIPG material on the contact surface using gasoline or alcohol.

1. 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 after applying FIPG.

1. Install the side bearing retainer with the 10 bolts.

   Torque:
     50 N*m{ 510 kgf*cm , 37 ft.*lbf }

28. 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):

     Item | Specified Condition
     New bearing | 0.98 to 1.75 N*m (10 to 16 kgf*cm, 8.7 to 14 in.*lbf)
     Reused bearing | 0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 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.

29. 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):
     0.22 to 0.88 N*m{ 6 to 9 kgf*cm , 1.9 to 8.8 in.*lbf } + drive pinion preload
   1. If necessary, disassemble and inspect the differential.

30. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION

1. 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 in.)
   1. If the backlash is not within the specification, adjust the side bearing preload.

31. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

1. Using a dial indicator, measure the runout of the 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 not within the specification, replace the companion flange.

32. STAKE DRIVE PINION NUT

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

33. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

1. Coat the lip of a new oil seal with MP grease.

1. Using SST and a plastic-faced hammer, tap in the oil seal until its surface is flush with the differential carrier end.

   SST
     09608-32010

   Oil seal depth:
     0 +- 0.45 m (0 +- 0.018 in.)

34. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR

1. Using a brass bar and hammer, tap in the side bearing retainer deflector.

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

35. INSTALL DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY

1. Install a new snap ring to the side gear inter shaft.

1. Using a plastic-faced hammer, tap the side gear inter shaft into the differential case.

1. Check that there is 2 to 3 mm (0.08 to 0.12 in.) of axial play.

1. Check that the side gear inter shaft cannot be completely pulled out by hand.

36. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY

1. Remove any old FIPG material on the contact surfaces of the differential and clutch case.

   NOTICE:
     Do not drop oil on the contact surfaces of the differential and clutch case.

1. Clean residual FIPG material on the contact surface using gasoline or alcohol.

1. 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 after applying FIPG.

1. Install the differential tube to the differential.

1. Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.

1. Apply adhesive to 2 or 3 threads of each bolt's end.

   Adhesive:
     Part No. 08833-00070, THREE BOND 1281 or equivalent

1. Install the 4 bolts.

   Torque:
     110 N*m{ 1,120 kgf*cm , 81 ft.*lbf }

37. INSTALL DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY

1. Remove any FIPG material from the contact surface of the differential and clutch case. Also, do not drop oil on the contact surfaces.

1. Clean residual FIPG material from the contact surfaces using gasoline or alcohol.

1. 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 after applying FIPG.

1. Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.

1. Install the actuator to the differential tube.

1. Apply adhesive to 2 or 3 threads of each bolt's end.

   Adhesive:
     Part No. 08833-00070, THREE BOND 1281 or equivalent

1. Install the 4 bolts.

   Torque:
     21 N*m{ 210 kgf*cm , 15 ft.*lbf }