Rear differential carrier ASSY
Components Removal / installation
AXLE / DIFFERENTIAL
REAR DIFFERENTIAL CARRIER ASSY
EXPLODED VIEW



REMOVAL
1. Draining of differential oil
(1) Remove the filler plug and the gasket.
(2) Remove the drain plug and the gasket, and then drain oil.
3. Removal of differential carrier ASSY RR
(1) Using a tall transmission jack, support the differential carrier ASSY RR.
WARNING:
·The differential carrier ASSY RR is heavy. Be sure to support it with a tall transmission jack.
·In order to prevent the differential carrier ASSY RR from being excessively tilted or coming off, perform the operation while holding it with several assistants.
·In order to prevent the differential carrier ASSY RR from being excessively tilted or coming off, perform the operation while holding it with several assistants.
(2) Remove 5 bolts, and then remove the rear differential mount stopper UPR and the rear differential mount stopper LWR.
(3) Lower the tall transmission jack slowly. Using a tire lever, etc., detach the rear drive shaft ASSY from the differential carrier ASSY RR as shown in the figure.
CAUTION:
If a tire lever, etc. contacts the rear cover, the cover may be damaged. A tire lever, etc. is allowed to contact the differential carrier.
(4) Lower the tall transmission jack. Pull out the rear drive shaft ASSY from the differential carrier ASSY RR, and then remove the differential carrier ASSY RR.
NOTE:
Suspend the detached rear drive shaft ASSY using a string, etc.
DISASSEMBLY
1. Fixation of rear differential carrier ASSY RR
(1) Install the rear differential carrier to the overhaul stand.
2. Removal of rear differential breather plug
(1) Remove the differential breather plug from the differential carrier.
3. Removal of rear differential carrier cover
(1) Remove the 8 bolts.
(2) Using a plastic hammer, lightly tap the rib portion of the differential carrier cover, and remove it from the differential carrier.
CAUTION:
Be careful not to damage the mating surface of the differential carrier.
4. Removal of rear differential breather plug oil deflector
(1) Remove the bolts, and then remove the breather plug oil deflector from the differential carrier cover.
5. Inspection of differential ring gear runout
(1) Inspect the runout of the ring gear by contacting a dial gauge at a right angle to the back surface of the ring gear.
Limit
: 0.07 mm {0.003 in}
NOTE:
If it exceeds the limit, remove the ring gear and inspect runout of the differential case.
6. Inspection of backlash between differential ring gear and differential drive pinion
(1) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(2) Secure the companion flange RR by hand, and inspect the ring gear backlash.
Standard value
: 0.13 to 0.18 mm {0.005 to 0.007 in}
NOTE:
Measure at 3 points or more on the ring gear circumference.
7. Inspection of tooth contact between differential ring gear and differential drive pinion
(1) Apply a thin uniform coat of red lead on both teeth surfaces of the ring gear.
(2) Rotate the companion flange RR forward and backward several times.
(3) Check the tooth contact between the drive pinion and the ring gear.

Captions in illustration
| *a |
Correct tooth contact |
*b |
Heel contact |
| *c |
Face contact |
*d |
Adjust the drive pinion and the ring gear in the direction of arrow. |
| *e |
Toe contact |
*f |
Flank contact |
NOTE:
·Check the tooth contact condition at 4 points on the ring gear circumference.
·The pattern shown on read lead is the position of tooth contact.
·The pattern shown on read lead is the position of tooth contact.
8. Inspection of differential side gear backlash
(1) Contact a dial gauge at a right angle to the tooth surface end of the differential side gear.
(2) Secure the differential pinion to the differential case side, and then check that the backlash of differential side gear is 0 mm {0 in}.
9. Inspection of rear drive pinion companion flange RR runout
(1) Wipe off the inner surface of the companion flange RR with a cloth to remove dust or foreign matter.
Captions in illustration
| *a |
Inspection of radial runout |
| *b |
Inspection of lateral runout |
(2) Inspection of companion flange RR radial runout
(a) Contact the lever type probe of a dial gauge at a right angle to the inner circumference of the companion flange RR.
(b) Inspect radial runout of the companion flange RR.
Limit
: 0.09mm {0.004in}
(3) Inspection of companion flange RR lateral runout
(a) Contact a dial gauge at a right angle to the surface of the companion flange RR as shown in the figure.
(b) Inspect lateral runout of the companion flange RR.
Limit
: 0.09mm {0.004in}
10. Inspection of differential drive pinion preload
(1) Using a socket wrench (30 mm) and a torque wrench, check preload of the drive pinion within the ring gear backlash.
Standard value:
Standard value:
Tightening torque=1.11 to 1.91N·m
{
11.3 to 19.5kgf·cm}
{0.82 to 1.41 ft·lbf}
11. Inspection of overall preload
(1) Using a socket wrench (30 mm) and a torque wrench, check overall preload with the drive pinion contacting the ring gear tooth surface.
Standard value:
Standard value:
Tightening torque=1.6 to 2.69N·m
{
16.3 to 27.4kgf·cm}
{1.18 to 1.98 ft·lbf}
12. Removal of rear differential side gear shaft oil seal
(1) Using a flat tip screwdriver, remove the right and left side oil seals from the differential carrier.
13. Removal of rear drive pinion nut
(1) Release the crimp of the drive pinion nut using a chisel and a hammer.
CAUTION:
In order to prevent the thread of the drive pinion from being damaged, completely release the crimp of the nut.
(2) Using the SST, secure the companion flange RR.
SST
18355AA000
18334AA000
Captions in illustration
| *a |
Drive |
| *b |
Hold |
(3) Using a socket wrench (30 mm), remove the drive pinion nut from the differential carrier.
WARNING:
During operation, support the overhaul stand.
14. Removal of rear drive pinion companion flange RR
(1) Using the SST, remove the companion flange RR from the differential carrier.
SST
09950-30012
09951-03010,
09953-03010,
09954-03010,
09955-03030,
09956-03030)
Captions in illustration
| *a |
Drive |
| *b |
Hold |
NOTE:
·Apply grease to the thread and end portions of the SST center bolt (09953-03010) before using it.
·The bolts and nuts used for securing the SST and the companion flange RR are recommended to be M8 × P1.25 with a bolt length of approx. 40 mm {1.6 in}.
·The bolts and nuts used for securing the SST and the companion flange RR are recommended to be M8 × P1.25 with a bolt length of approx. 40 mm {1.6 in}.
15. Removal of rear differential dust deflector
NOTE:
Perform the operation only when the dust deflector is damaged.
(1) Using the SST and a press, remove the dust deflector from the companion flange RR.
SST
09950-00020
499877000
CAUTION:
Be careful not to drop the companion flange RR.
NOTE:
In order to ensure the contact surface between the SST and the dust deflector, perform the operation while tightening the nut of the SST.
17. Removal of rear differential drive pinion oil slinger
(1) Using a magnet hand, remove the oil slinger from the differential carrier.
18. Removal of rear drive pinion tapered roller bearing FR
19. Removal of rear differential drive pinion bearing spacer
(1) Remove the bearing spacer from the drive pinion.
20. Removal of rear differential carrier
(1) Place an identification mark on the bearing cap and the differential carrier.
Captions in illustration
| *a |
Identification mark |
NOTE:
Place an identification mark on one end only.
(2) Remove 4 bolts, and remove 2 bearing caps from the differential carrier.
CAUTION:
The bearing cap and the carrier are manufactured as a unit; do not change the combination.
(3) Using the SST and a plastic hammer, remove the right and left side gear shaft washers from the differential carrier.
SST
09504-22012
NOTE:
·For reference when reassembling, record thickness of the right and left (back face side and tooth face side) side gear shaft washers.
·Place a right or left identification mark (back face side or tooth face side) on the side gear shaft washers, and arrange them separately.
·Place a right or left identification mark (back face side or tooth face side) on the side gear shaft washers, and arrange them separately.
(4) Remove the differential case and the case bearing (outer race) as a single unit from the differential carrier.
CAUTION:
Be careful not to damage the differential case bearing and the ring gear.
NOTE:
Place a right or left identification mark (back face side or tooth face side) on the case bearing (outer race), and arrange them separately.
21. Removal of rear drive pinion tapered roller bearing RR
(1) Remove the drive pinion from the differential carrier.
(2) Using the SST and a press, remove the tapered roller bearing RR (inner race) from the drive pinion.
SST
09950-00020
CAUTION:
Be careful not to drop the drive pinion.
NOTE:
In order to ensure the contact surface between the SST and the tapered roller bearing RR (inner race), perform the operation while tightening the nut of the SST.
(3) Remove the drive pinion washer from the drive pinion.
NOTE:
For reference when reassembling, record thickness of the drive pinion washer.
(4) Using a brass bar and a hammer, lightly and evenly tap the entire perimeter of the tapered roller bearing RR (outer race), and remove it from the differential carrier.
Captions in illustration
| *1 |
Outer race |
CAUTION:
Always let the brass bar come in contact with the range of the tapered roller bearing RR (outer race) during operation. Be careful not to damage the differential carrier.
22. Removal of rear drive pinion tapered roller bearing FR
(1) Using a brass bar and a hammer, lightly and evenly tap the entire perimeter of the tapered roller bearing FR (outer race), and remove it from the differential carrier.
Captions in illustration
| *1 |
Outer race |
CAUTION:
Always let the brass bar come in contact with the range of the tapered roller bearing RR (outer race) during operation. Be careful not to damage the differential carrier.
23. Removal of differential ring gear
(1) Using aluminum plates in between, secure the differential case in a vise.
CAUTION:
Do not vise excessively.
(2) Place an alignment mark on the differential case and the ring gear.
Captions in illustration
| *a |
Alignment marks |
(3) Release the crimps of 5 lock plates using a chisel and a hammer.
(4) Remove 10 bolts and 5 lock plates from the differential case.
(5) Using a plastic hammer, evenly tap the periphery of the ring gear, and remove the ring gear from the differential case.
NOTE:
Cover the tooth surface side of the ring gear with a cloth to prevent damage.
24. Inspection of differential case ASSY runout
NOTE:
Perform only when the inspection result of the differential ring gear runout exceeds the limit.
(1) Install the case bearing (outer race LH/RH) to the case bearing (inner race LH/RH), and install the differential case to the differential carrier.
CAUTION:
·When installing the bearing outer races, do not confuse the left and right.
·Be careful not to damage the differential case bearing.
·Be careful not to damage the differential case bearing.
(2) Install the right and left (back face side and tooth face side) side gear shaft washer to the differential carrier while avoiding play of the case bearing.

Captions in illustration
| *a |
Back face side |
*b |
Tooth face side |
(3) Install the right and left bearing caps to the differential carrier with 4 bolts.
Standard value:
Captions in illustration
| *a |
Identification mark |
Standard value:
Tightening torque=85N·m
{
867kgf·cm}
{62.7ft·lbf}
CAUTION:
The bearing cap and the carrier are manufactured as a unit; do not change the combination.
(4) Contact a dial gauge at a right angle to the flange surface of the differential case.
(5) Check runout of the differential case.
Limit
: 0.07 mm {0.003 in}
(6) Remove 4 bolts, and remove 2 bearing caps from the differential carrier.
(7) Remove the differential case, right and left case bearings and right and left side gear shaft washers from the differential carrier.
CAUTION:
Be careful not to damage the differential case bearing.
25. Removal of rear differential case bearing
NOTE:
Perform the operation only when the case bearing or the differential case is replaced.
(1) Using the SST, remove the case bearings (inner race LH and RH) from the differential case.
SST
09950-40011
09951-04020,
09952-04010,
09953-04030,
09954-04010,
09955-04061,
09957-04010,
09958-04011)
09950-60010
09951-00350,
09951-00480,
09952-06010)
Captions in illustration
| *a |
Drive |
| *b |
Hold |
CAUTION:
Be careful not to deform the cage of the differential case bearing. (When the bearing is reused)
NOTE:
·Apply grease to the thread and end portions of the SST center bolt (09953-04030) before using it.
·Pinch the bearing inner race from the cutout portion of the differential case using the claws of the SST.
·Place a right or left identification mark (back face side or tooth face side) on the differential case bearings, and arrange them separately.
·Pinch the bearing inner race from the cutout portion of the differential case using the claws of the SST.
·Place a right or left identification mark (back face side or tooth face side) on the differential case bearings, and arrange them separately.
26. Inspection of differential side gear backlash
(1) Using aluminum plates in between, secure the differential case in a vise.
CAUTION:
Do not vise excessively.
(2) Contact a dial gauge at a right angle to the tooth surface end of the differential side gear, secure the differential pinion gear to the differential case, and then check that the backlash is 0 mm {0 in}.
NOTE:
If the backlash is not 0 mm {0 in}, replace the differential case ASSY.
ASSEMBLY
1. Installation of differential ring gear
(1) Clean the screw hole of the differential case.
(2) Heat the ring gear up to 100°C {212°F} with hot water.
WARNING:
The ring gear becomes hot. Perform the operation after protecting hands with thick gloves.
(3) Completely wipe off grease and water from the mating surface of the differential case and the ring gear.
(4) Using aluminum plates in between, secure the differential case in a vise.
CAUTION:
Do not vise excessively.
(5) Completely wipe off grease and water from the ring gear (mating surface of the differential case).
(6) Align the alignment marks on the differential case and the ring gear, and then quickly install the ring gear to the differential case.
Captions in illustration
| *a |
Alignment marks |
CAUTION:
Align the bolt hole of the differential case and the screw hole of the ring gear.
(7) Temporarily tighten 10 differential case bolts several times through 5 new lock plates, and then tighten them to the specified torque.
Standard value:
Standard value:
Tightening torque=97N·m
{
989kgf·cm}
{71.5ft·lbf}
CAUTION:
Tighten the bolts after the ring gear cools down sufficiently.
NOTE:
Tighten the bolts diagonally in several stages.
(8) Release the crimps of the lock plate using a chisel and a hammer to counter the rotation.
Captions in illustration
| *a |
Tightening direction |
NOTE:
If the crimp contacts the angled portion of the bolt head and should be divided into 2 sections, the section facing the tightening side of the bolt head must be in close contact as shown in the figure.
2. Installation of rear differential case bearing
(1) Using the SST and a press, press-fit the case bearings (inner race LH and RH) into the differential case.
SST
09710-30012
09710-04081)
398477702
NOTE:
·Press until the case bearing is in close contact with the differential case.
·Align the SST in the center of the differential case.
·Align the SST in the center of the differential case.
CAUTION:
·When using new bearings, do not apply differential gear oil.
·Be careful not to deform the cage of the bearing.
·When replacing the bearing, replace the outer race and the inner race as a set.
·Be careful not to deform the cage of the bearing.
·When replacing the bearing, replace the outer race and the inner race as a set.
3. Inspection of differential ring gear runout
(1) Install the case bearing (outer race LH and RH) to the case bearing (inner race LH and RH), and install the differential case to the carrier.
CAUTION:
·When installing the bearing outer races, do not confuse the left and right.
·When using new bearings, do not apply differential gear oil.
·When using new bearings, do not apply differential gear oil.
(2) Install the right and left (back face side and tooth face side) side gear shaft washer to the differential carrier while avoiding play of the case bearing.

Captions in illustration
| *a |
Back face side |
*b |
Tooth face side |
NOTE:
·When the final gear set (drive pinion & ring gear) and the case bearings are replaced, select a side gear shaft washer with thin thickness and install it.
·When the drive pinion, ring gear and case bearings are reused, select a side gear shaft washer with the same thickness as that of the one before disassembly and install it.
·When the drive pinion, ring gear and case bearings are reused, select a side gear shaft washer with the same thickness as that of the one before disassembly and install it.
(3) Install the right and left bearing caps to the differential carrier with 4 bolts.
Standard value:
Captions in illustration
| *a |
Identification mark |
Standard value:
Tightening torque=85N·m
{
867kgf·cm}
{62.7ft·lbf}
CAUTION:
The bearing cap and the carrier are manufactured as a unit; do not change the combination.
(4) Contact a dial gauge at a right angle to the back surface of the ring gear.
(5) Check for runout of the ring gear.
Limit
: 0.07 mm {0.003 in}
(6) Remove 4 bolts, and remove 2 bearing caps from the differential carrier.
Captions in illustration
| *a |
Identification mark |
(7) Remove the right and left side gear shaft washers from the differential carrier.

Captions in illustration
| *a |
Back face side |
*b |
Tooth face side |
(8) Remove the differential case and right and left case bearings from the differential carrier.
CAUTION:
Be careful not to damage the differential case bearing and the ring gear.
4. Installation of rear drive pinion tapered roller bearing RR
(1) Install the drive pinion washer to the drive pinion.
Captions in illustration
| *1 |
Drive pinion washer |
| *2 |
Inner race |
NOTE:
·In order to prevent the drive pinion washer from dropping, temporarily install the tapered roller bearing RR (inner race).
·Install the drive pinion washer with the same thickness as that of the removed one.
·The drive pinion washer has no installation direction.
·Install the drive pinion washer with the same thickness as that of the removed one.
·The drive pinion washer has no installation direction.
(2) Using the SST and a press, press-fit the tapered roller bearing RR (inner race) into the drive pinion.
SST
09506-30012
CAUTION:
When using new bearings, do not apply differential gear oil.
5. Installation of rear drive pinion tapered roller bearing FR
6. Installation of rear differential dust deflector
(1) Using the SST and a press, press-fit a new dust deflector into the companion flange RR.
SST
499277200
499225500
CAUTION:
·When press-fitting, gradually insert the dust deflector while checking the condition.
·Do not press-fit excessively.
·Remove a burr if it occurs when press-fitting.
·Do not press-fit excessively.
·Remove a burr if it occurs when press-fitting.
7. Adjustment of differential drive pinion preload
(1) While supporting the drive pinion by hand, install the drive pinion tapered roller bearing FR (inner race) to the differential carrier.
CAUTION:
·Be careful not to drop the drive pinion.
·In order to check the tooth contact of the ring gear, install the spacer and oil seal after checking and adjusting the tooth contact.
·When using new bearings, do not apply differential gear oil.
·In order to check the tooth contact of the ring gear, install the spacer and oil seal after checking and adjusting the tooth contact.
·When using new bearings, do not apply differential gear oil.
(2) Install the oil slinger to the differential carrier.
(3) Using the SST, install the companion flange RR to the differential carrier.
SST
09950-30012
09951-03010,
09953-03010,
09954-03010,
09955-03030,
09956-03030)
Captions in illustration
| *a |
Drive |
| *b |
Hold |
CAUTION:
·Be careful not to drop the drive pinion. Support it by hands until the SST is installed.
·The bearing spacer is not installed, therefore, install the companion flange RR until there is a small play in the drive pinion.
·The bearing spacer is not installed, therefore, install the companion flange RR until there is a small play in the drive pinion.
NOTE:
·Apply grease to the thread and end portions of the SST center bolt (09953-03010) before using it.
·The bolts and nuts used for securing the SST and the companion flange RR are recommended to be M8 × P1.25 with a bolt length of approx. 40 mm {1.6 in}.
·The bolts and nuts used for securing the SST and the companion flange RR are recommended to be M8 × P1.25 with a bolt length of approx. 40 mm {1.6 in}.
(4) Using the SST, secure the companion flange RR.
SST
18355AA000
18334AA000
Captions in illustration
| *a |
Drive |
| *b |
Hold |
(5) Using a socket wrench (30 mm) and a torque wrench, gradually tighten a new drive pinion nut to the specified preload.
Limit
: T = 338 N·m {3447 kgf·cm} {249.3 ft·lbf}
WARNING:
During operation, support the overhaul stand.
CAUTION:
Note that no bearing spacer is inserted. Therefore, tighten the nut gradually. Never overtighten it.
NOTE:
·Tighten to approx. 100 N·m {1020 kgf·cm} {73.8 ft·lbf} while checking the preload.
·Apply differential gear oil to the thread portions of the nut and the drive pinion.
·Apply differential gear oil to the thread portions of the nut and the drive pinion.
(6) Turn it forward and backward several times to seat the bearing properly.
(7) Using a socket wrench (30 mm) and a torque wrench, check preload of the drive pinion.
Standard value
| Specifications |
Preload (N·m {kgf·cm} {ft·lbf}) |
|---|---|
| When the bearing is new |
1.39 to 2.49 {14.2 to 25.4} {1.03 to 1.84} |
| When the bearing is reused |
1.01 to 1.81 {10.3 to 18.5} {0.74 to 1.33} |
CAUTION:
For inspection of overall preload, record the preload.
8. Installation of rear differential case SUB-ASSY
(1) Install the case bearing (outer race LH and RH) to the case bearing (inner race LH and RH), and install the differential case to the differential carrier.
CAUTION:
When installing the bearing outer races, do not confuse the left and right.
(2) Install the right and left (back face side and tooth face side) side gear shaft washer to the differential carrier while avoiding play of the case bearing.

Captions in illustration
| *a |
Back face side |
*b |
Tooth face side |
NOTE:
·When the final gear set (drive pinion & ring gear) and the differential case bearings are replaced, select a differential side gear shaft washer with thin thickness and install it.
·When the drive pinion, ring gear and differential case bearings are reused, select a differential side gear shaft washer with the same thickness as that of the disassembled one and install it.
·When the drive pinion, ring gear and differential case bearings are reused, select a differential side gear shaft washer with the same thickness as that of the disassembled one and install it.
9. Inspection and adjustment of backlash between differential ring gear and differential drive pinion
(1) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(2) Secure the companion flange RR by hand, and inspect the ring gear by moving it.
Standard value
: 0.13 to 0.18 mm {0.005 to 0.007 in}
NOTE:
·Inspect at 3 points or more on the ring gear circumference.
·Record the measured value for reference when selecting the side gear shaft washer.
·For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
·Record the measured value for reference when selecting the side gear shaft washer.
·For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
(3) Select the side gear shaft washer which allows the ring gear’s backlash to be within the standard value, and install it to the back face side of the ring gear.
Type of rear differential side gear shaft washer
| Thickness (mm {in}) |
Identification mark |
Thickness (mm {in}) |
Identification mark |
|---|---|---|---|
| 2.57 to 2.59 {0.1012 to 0.1020} |
01 |
3.03 to 3.05 {0.1193 to 0.1201} |
47 |
| 2.59 to 2.61 {0.1020 to 0.1028} |
32 |
3.05 to 3.07 {0.1201 to 0.1209} |
17 |
| 2.61 to 2.63 {0.1028 to 0.10315} |
33 |
3.07 to 3.09 {0.1209 to 0.1217} |
48 |
| 2.63 to 2.65 {0.1035 to 0.1043} |
03 |
3.09 to 3.11 {0.1217 to 0.1224} |
49 |
| 2.65 to 2.67 {0.1043 to 0.1051} |
34 |
3.11 to 3.13 {0.1224 to 0.1232} |
19 |
| 2.67 to 2.69 {0.1051 to 0.1059} |
35 |
3.13 to 3.15 {0.1232 to 0.1240} |
50 |
| 2.69 to 2.71 {0.1059 to 0.1067} |
05 |
3.15 to 3.17 {0.1240 to 0.1248} |
51 |
| 2.71 to 2.73 {0.1067 to 0.1075} |
36 |
3.17 to 3.19 {0.1248 to 0.1256} |
21 |
| 2.73 to 2.75 {0.1075 to 0.1083} |
37 |
3.19 to 3.21 {0.1256 to 0.1264} |
52 |
| 2.75 to 2.77 {0.1083 to 0.1091} |
07 |
3.21 to 3.23 {0.1264 to 0.1272} |
53 |
| 2.77 to 2.79 {0.1091 to 0.1098} |
38 |
3.23 to 3.25 {0.1272 to 0.1280} |
23 |
| 2.79 to 2.81 {0.1098 to 0.1106} |
39 |
3.25 to 3.27 {0.1280 to 0.1287} |
54 |
| 2.81 to 2.83 {0.1106 to 0.1114} |
09 |
3.27 to 3.29 {0.1287 to 0.1295} |
55 |
| 2.83 to 2.85 {0.1114 to 0.1122} |
40 |
3.29 to 3.31 {0.1295 to 0.1303} |
25 |
| 2.85 to 2.87 {0.1122 to 0.1130} |
41 |
3.31 to 3.33 {0.1303 to 0.1311} |
56 |
| 2.87 to 2.89 {0.1130 to 0.1138} |
11 |
3.33 to 3.35 {0.1311 to 0.1319} |
57 |
| 2.89 to 2.91 {0.1138 to 0.1146} |
42 |
3.35 to 3.37 {0.1319 to 0.1327} |
27 |
| 2.91 to 2.93 {0.1146 to 0.1154} |
43 |
3.37 to 3.39 {0.1327 to 0.1335} |
58 |
| 2.93 to 2.95 {0.1154 to 0.1161} |
13 |
3.39 to 3.41 {0.1335 to 0.1343} |
59 |
| 2.95 to 2.97 {0.1161 to 0.1169} |
44 |
3.41 to 3.43 {0.1343 to 0.1350} |
29 |
| 2.97 to 2.99 {0.1169 to 0.1177} |
45 |
3.43 to 3.45 {0.1350 to 0.1358} |
60 |
| 2.99 to 3.01 {0.1177 to 0.1185} |
15 |
3.45 to 3.47 {0.1358 to 0.1366} |
61 |
| 3.01 to 3.03 {0.1185 to 0.1193} |
46 |
3.47 to 3.49 {0.1366 to 0.1374} |
31 |
(4) Using a plastic hammer, lightly tap the differential carrier for better fitting of the case bearing and the side gear shaft washer.
(5) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(6) Secure the companion flange RR by hand, and inspect the backlash by moving the ring gear.

Standard value
: 0.13 to 0.18 mm {0.005 to 0.007 in}

(7) If out of the standard, select the side gear shaft washer which allows the ring gear’s backlash to be around the standard value, and install it to the back face side of the ring gear.
(8) Select the thickest side gear shaft washer that provides no gap or almost no gap between the end face of the case bearing outer race on the tooth face side of the ring gear and the carrier.
Captions in illustration
| *1 |
Side gear shaft washer |
| *2 |
Outer race |
(9) Using a plastic hammer, lightly tap the differential carrier for better fitting of the case bearing.
(10) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(11) Secure the companion flange RR by hand, and inspect the backlash by moving the ring gear.
Standard value
: 0.13 to 0.18 mm {0.005 to 0.007 in}
(12) If out of the standard, adjust the thickness of the right and left side gear shaft washers, increasing or decreasing by the same amount.
NOTE:
·Record the measured value for reference when selecting the side gear shaft washer.
·For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
·For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
10. Inspection and adjustment of differential case bearing preload
(1) After adjusting the backlash of the ring gear, remove the side gear shaft washer on the tooth face side of the ring gear.
(2) Using a micrometer, inspect the thickness of the side gear shaft washer.
(3) Select the side gear shaft washer that is 0.06 to 0.09 mm {0.002 to 0.004 in} thicker than the removed side gear shaft washer.
CAUTION:
Install the side gear shaft washer that can be inserted into about two thirds of the way using a finger.
(4) Using the SST and a hammer, press-fit the side gear shaft washers into the differential carrier.
SST
09504-22012
(5) Align the alignment marks on the bearing cap and the differential carrier, and install the bearing cap.
Captions in illustration
| *a |
Identification mark |
(6) Using 4 bolts, tighten the right and left bearing caps.
Standard value:
Standard value:
Tightening torque=85N·m
{
867kgf·cm}
{62.7ft·lbf}
CAUTION:
The bearing cap and the carrier are manufactured as a unit; do not change the combination.
(7) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(8) Secure the companion flange RR by hand, and inspect the backlash by moving the ring gear.
Standard value
: 0.13 to 0.18 mm {0.005 to 0.007 in}
NOTE:
·Measure at 3 points or more on the ring gear circumference.
·If any small backlash is found, replace the side gear shaft washer on the tooth face side of the ring gear with a thicker one.
·Record the measured value for reference when selecting the side gear shaft washer.
·For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
·When adjusting the backlash, bring the average value close to 0.1 mm {0.004 in}.
·If any small backlash is found, replace the side gear shaft washer on the tooth face side of the ring gear with a thicker one.
·Record the measured value for reference when selecting the side gear shaft washer.
·For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
·When adjusting the backlash, bring the average value close to 0.1 mm {0.004 in}.
11. Inspection and adjustment of overall preload
(1) Using a socket wrench (30 mm) and a torque wrench, check overall preload with the drive pinion contacting the ring gear tooth surface.
Standard value
| Specifications |
Preload with new drive pinion tapered roller bearing (N·m {kgf·cm} {fb·lbf}) |
Preload with reused drive pinion tapered roller bearing (N·m {kgf·cm} {fb·lbf}) |
|---|---|---|
| When the differential case bearing is new |
2.47 to 4.16 {25.2 to 42.4} {1.82 to 3.07} |
2.09 to 3.48 {21.3 to 35.5} {1.54 to 2.57} |
| When the differential case bearing is reused |
1.88 to 3.27 {19.2 to 33.3} {1.39 to 2.41} |
1.5 to 2.59 {15.3 to 26.4} {1.11 to 1.91} |
NOTE:
·If out of the standard, perform the adjustment using the side gear shaft washer on the tooth face side of the ring gear.
·If the measured preload is less than standard, replace the side gear shaft washer with a thicker one.
·If the measured preload is more than standard, replace the side gear shaft washer with a thinner one.
·Record the measured value for reference when reassembling.
·If the measured preload is less than standard, replace the side gear shaft washer with a thicker one.
·If the measured preload is more than standard, replace the side gear shaft washer with a thinner one.
·Record the measured value for reference when reassembling.
(2) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(3) Secure the companion flange RR by hand, and inspect the backlash by moving the ring gear.
Standard value
: 0.13 to 0.18 mm {0.005 to 0.007 in}
NOTE:
·Measure at 3 points or more on the ring gear circumference.
·If the backlash is out of the standard, adjust the thickness of the right and left side gear shaft washers, increasing or decreasing by the same amount.
·When adjusting the backlash, bring the average value close to 0.1 mm {0.004 in}.
·If any small backlash is found, replace the side gear shaft washer on the tooth face side of the ring gear with a thicker one.
·Record the measured value for reference when selecting the side gear shaft washer.
·For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
·If the backlash is out of the standard, adjust the thickness of the right and left side gear shaft washers, increasing or decreasing by the same amount.
·When adjusting the backlash, bring the average value close to 0.1 mm {0.004 in}.
·If any small backlash is found, replace the side gear shaft washer on the tooth face side of the ring gear with a thicker one.
·Record the measured value for reference when selecting the side gear shaft washer.
·For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
(4) Recheck the overall preload.
12. Inspection of tooth contact between differential ring gear and differential drive pinion
(1) Apply a thin uniform coat of red lead on both teeth surfaces of the ring gear.
(2) Rotate the companion flange forward and backward several times.
(3) Check the tooth contact between the drive pinion and the ring gear.

Captions in illustration
| *a |
Correct tooth contact |
*b |
Heel contact |
| *c |
Face contact |
*d |
Adjust the drive pinion and the ring gear in the direction of arrow. |
| *e |
Toe contact |
*f |
Flank contact |
NOTE:
·Check the contact condition at 4 points on the ring gear circumference.
·The pattern shown on read lead is the position of tooth contact.
·The pattern shown on read lead is the position of tooth contact.
(4) If an improper tooth contact occurs, select a drive pinion washer from the table, remove the tapered roller bearing RR, and then reinstall it.
Captions in illustration
| *1 |
Inner race |
| *2 |
Drive pinion washer |
CAUTION:
If the thickness of the drive pinion washer is changed, adjust the backlash and perform the general preload inspection.
Type of rear differential drive pinion washer
| 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} |
2.20 to 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} |
13. Removal of rear drive pinion nut
(1) Using the SST, secure the flange and remove the drive pinion nut from the differential carrier.
SST
18355AA000
18334AA000
Captions in illustration
| *a |
Drive |
| *b |
Hold |
WARNING:
During operation, support the overhaul stand.
NOTE:
The bolts and nuts used for securing the SST and the companion flange RR are recommended to be M8 × P1.25 with a bolt length of approx. 45 mm {1.8 in}.
17. Installation of rear differential drive pinion bearing spacer
(1) Install a new bearing spacer to the drive pinion.
CAUTION:
Install the part with a larger inner diameter to the drive pinion side, and the part with a smaller to the companion flange RR side.
18. Installation of rear drive pinion tapered roller bearing FR
(1) Install the tapered roller bearing FR (inner race) to the differential carrier.
19. Installation of rear differential drive pinion oil slinger
(1) Install the oil slinger to the differential carrier.
20. Installation of rear drive pinion companion flange RR
(1) Using the SST and the companion flange RR, press-fit the tapered roller bearing RR (inner race) into the differential carrier.
SST
09950-30012
09951-03010,
09953-03010,
09954-03010,
09955-03030,
09956-03030)
Captions in illustration
| *a |
Drive |
| *b |
Hold |
NOTE:
·Apply grease to the thread and end portions of the SST center bolt (09953-03010) before using it.
·The bolts and nuts used for securing the SST and the companion flange RR are recommended to be M8 × P1.25 with a bolt length of approx. 40 mm {1.6 in}.
·The bolts and nuts used for securing the SST and the companion flange RR are recommended to be M8 × P1.25 with a bolt length of approx. 40 mm {1.6 in}.
23. Installation of rear drive pinion companion flange RR
(1) Using the SST, install the companion flange RR to the differential carrier.
SST
09950-30012
09951-03010,
09953-03010,
09954-03010,
09955-03030,
09956-03030)
Captions in illustration
| *a |
Drive |
| *b |
Hold |
NOTE:
·Apply grease to the thread and end portions of the SST center bolt (09953-03010) before using it.
·The bolts and nuts used for securing the SST and the companion flange RR are recommended to be M8 × P1.25 with a bolt length of approx. 40 mm {1.6 in}.
·The bolts and nuts used for securing the SST and the companion flange RR are recommended to be M8 × P1.25 with a bolt length of approx. 40 mm {1.6 in}.
(2) Using the SST, secure the companion flange RR.
SST
18355AA000
18334AA000
Captions in illustration
| *a |
Drive |
| *b |
Hold |
(3) Using a socket wrench (30 mm) and a torque wrench, tighten the drive pinion nut while checking the preload.
Limit
: T = 338 N·m {3447 kgf·cm} {249.3 ft·lbf}
WARNING:
During operation, support the overhaul stand.
CAUTION:
Do not tighten excessively, or the thread portion may be damaged if it exceeds the limit.
NOTE:
·Tighten to approx. 100 N·m {1020 kgf·cm} {73.8 ft·lbf} while checking the preload.
·Apply differential gear oil to the thread portions of the nut and the drive pinion.
·Apply differential gear oil to the thread portions of the nut and the drive pinion.
24. Adjustment of differential drive pinion preload
(1) Using a socket wrench (30 mm) and a torque wrench, check preload within the backlash of the drive pinion and ring gear.
Standard value
| Specifications |
Preload (N·m {kgf·cm} {ft·lbf}) |
|---|---|
| When the bearing is new |
1.49 to 2.59 {15.2 to 26.4} {1.1 to 1.91} |
| When the bearing is reused |
1.11 to 1.91 {11.3 to 19.5} {0.82 to 1.41} |
NOTE:
·In order to seat the bearing properly, rotate the companion flange forward and backward several times.
·For inspection of general preload, record the preload of the drive pinion.
·For inspection of general preload, record the preload of the drive pinion.
(2) Replace the bearing spacer if preload is excessive.
CAUTION:
The bearing spacer is used in plastic deformation, therefore, always replace it with a new part if excessively high preload is set to the drive pinion by mistake.
(3) If the preload is insufficient, check the preload after further tightening the drive pinion nut by 5 to 10°, and repeat the adjustment to be within the standard.
Limit
: T = 338 N·m {3447 kgf·cm} {249.3 ft·lbf}
(4) If the preload is still insufficient after the tightening torque of the drive pinion nut exceeds the limit, loosen the drive pinion nut, and then check that the drive pinion nut and drive pinion thread are not and broken.
(5) If there is no malfunction, replace the bearing spacer, apply differential gear oil to the thread of the drive pinion, and repeat the operation.
25. Inspection of overall preload
(1) Using a socket wrench (30 mm) and a torque wrench, check preload with the drive pinion contacting the ring gear tooth surface.
Standard value
| Specifications |
Preload with new drive pinion tapered roller bearing (N·m {kgf·cm} {ft·lbf}) |
Preload with reused drive pinion tapered roller bearing (N·m {kgf·cm} {ft·lbf}) |
|---|---|---|
| When the differential case bearing is new |
2.57 to 4.26 {26.2 to 43.4} {1.9 to 3.14} |
2.19 to 3.58 {22.3 to 36.5} {1.62 to 2.64} |
| When the differential case bearing is reused |
1.98 to 3.37 {20.2 to 34.4} {1.46 to 2.49} |
1.6 to 2.69 {16.3 to 27.4} {1.18 to 1.98} |
26. Inspection of backlash between differential ring gear and differential drive pinion
(1) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(2) Secure the companion flange RR by hand, and inspect the ring gear backlash.
Standard value
: 0.13 to 0.18 mm {0.005 to 0.007 in}
NOTE:
Measure at 3 points or more on the ring gear circumference.
27. Inspection of rear drive pinion companion flange RR runout
(1) Wipe off the inner surface of the companion flange RR with a cloth to remove dust or foreign matter.
Captions in illustration
| *a |
Inspection of radial runout |
| *b |
Inspection of lateral runout |
(2) Inspection of companion flange RR radial runout
(a) Contact the lever type probe of a dial gauge at a right angle to the inner circumference of the companion flange RR.
(b) Inspect radial runout of the companion flange RR.
Limit
: 0.09mm {0.004in}
(3) Inspection of companion flange RR lateral runout
(a) Contact a dial gauge at a right angle to the surface of the companion flange RR as shown in the figure.
(b) Inspect lateral runout of the companion flange RR.
Limit
: 0.09mm {0.004in}
28. Fixation of rear drive pinion nut
(1) Crimp the drive pinion nut using a chisel and a hammer.
30. Installation of rear differential drain plug
(1) Install the drain plug to the differential carrier through a new gasket using a socket hexagon wrench 10.
Standard value:
Standard value:
Tightening torque=49N·m
{
500kgf·cm}
{36.1ft·lbf}
31. Installation of rear differential breather plug oil deflector
(1) Using a scraper and a wire brush, clean the seal gasket that is attached to the differential carrier and the carrier cover, and then degrease it with a cleaning solvent, etc.
CAUTION:
Be careful not to damage the mating surface of the differential carrier.
(2) Using bolts, install the breather plug oil deflector to the differential carrier cover.
Standard value:
Standard value:
Tightening torque=8.0N·m
{
82kgf·cm}
{5.9ft·lbf}
32. Installation of rear differential carrier cover
(1) Apply Three Bond 1281 or equivalent to the position of the differential carrier cover as shown in the figure.
Captions in illustration
| *a |
Applying position of Three Bond 1281 or equivalent |
CAUTION:
·Apply seal gasket in a diameter of 2 to 3 mm {0.08 to 0.12 in} seamlessly.
·There must be 10 mm {0.4 in} or more overlapped portion between the starting and ending sections.
·Install within 3 minutes after applying seal gasket.
·There must be 10 mm {0.4 in} or more overlapped portion between the starting and ending sections.
·Install within 3 minutes after applying seal gasket.
(2) Install the differential carrier cover to the differential carrier with 8 bolts.
Standard value:
Standard value:
Tightening torque=47N·m
{
479kgf·cm}
{34.7 ft·lbf}
CAUTION:
Do not fill with oil or drive the vehicle immediately after installing the differential carrier cover. Leave the vehicle unattended for one hour or more. Also, avoid abrupt acceleration and deceleration for 12 hours or more.
33. Installation of rear differential breather plug
(1) Install the differential breather plug to the differential carrier.
Standard value:
Standard value:
Tightening torque=21N·m
{
214kgf·cm}
{15.5ft·lbf}
34. Removal of rear differential carrier ASSY RR
(1) Remove the rear differential carrier ASSY RR from the overhaul stand.
INSTALLATION
1. Installation of differential carrier ASSY RR
(1) Using a tall transmission jack, support the differential carrier ASSY RR.
(2) Install a new snap ring to the rear drive shaft ASSY.
(3) Apply differential gear oil to the spline of the inboard joint ASSY.
(4) Align the spline of the rear drive shaft inboard joint, and then press-fit the rear drive shaft ASSY using a brass bar and a hammer.
CAUTION:
·Place the snap ring with its cut end facing downward.
·Do not damage the oil seal during insertion.
·Be careful not to strike the tip of the outboard joint with a hammer.
·If there is a malfunction, such as dislocation, etc., in the inboard joint of the drive shaft, replace it with a new part.
·Do not damage the oil seal during insertion.
·Be careful not to strike the tip of the outboard joint with a hammer.
·If there is a malfunction, such as dislocation, etc., in the inboard joint of the drive shaft, replace it with a new part.
NOTE:
Check that the drive shaft is completely press-fit by feeling the change of reaction force or sound quality.
(5) Gradually lift the tall transmission jack, and install the differential carrier ASSY RR through the rear differential mount stopper UPR and the rear differential mount stopper LWR with 5 bolts
Standard value:
Standard value:
Tightening torque=62N·m
{
632kgf·cm}
{45.7 ft·lbf} (bolt A)
Tightening torque=95N·m { 969kgf·cm} {70.1 ft·lbf} (bolt B)
Tightening torque=95N·m { 969kgf·cm} {70.1 ft·lbf} (bolt B)