Rear Differential: Assembly

• Assemble in the reverse order of disassembling.
• Check and adjust each part during assembly.
• Keep the shims and washers in order, so that they are not mis-installed.
• Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed.
• Apply gear oil when installing the bearings and thrust washers.
• Be careful not to mix up the right and left hand cups of the bearings.
• Replace the oil seal with new one at every disassembly. Apply chassis grease between the lips when installing the oil seal.
  Fig 1: Applying Chassis Grease To Oil Seal

  

1. Press rear bearing race into differential carrier with ST1 and ST2.

   ST1 398477701 HANDLE

   ST2 398477703 DRIFT 2

   Fig 2: Pressing Rear Bearing Race Into Differential Carrier

   
2. Insert ST1 into case with pinion height adjusting washer and rear bearing cone fitted onto it.
   CAUTION:

   • Re-use the used washer if not deformed.
   • Use a new rear bearing cone.
3. Then install preload adjusting spacer and washer, front bearing cone, ST2, companion flange, and washer and drive pinion nut.

   ST1 398507702 DUMMY SHAFT

   ST2 398507703 DUMMY COLLAR

   Fig 3: Installing Components Into Differential Carrier

   
4. Turn ST1 with hand to make it seated, and tighten drive pinion nut while measuring the preload with spring balance. Select preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque.

   ST1 398507704 BLOCK

   ST2 398507702 DUMMY SHAFT

   CAUTION: Use a new lock nut.
   NOTE:

   • Be careful not to give excessive preload.
   • When tightening the drive pinion nut, lock ST1 with ST2 as shown in the figure. See Fig 4 .

   Tightening torque:  181+/-15 N.m (18.5+/-1.5 kg-m, 134+/-11 ft-lb)

   Fig 4: Tightening Drive Pinion Nut & Identifying ST1 & ST2 Placement

   
   Fig 5: Specifications Front & Rear Bearing Preload

   
   Fig 6: Checking For Specified Preload

   
   Fig 7: Identifying Preload Adjustment Washers & Spacers Chart

   

Adjust drive pinion height with shim installed between rear bearing cone and the back of pinion gear.

1. Install ST1, ST2, and ST3, see Fig 9 , and apply the specified preload on the bearings.
   Fig 8: Identifying Specified Preload Of Bearings

   

   Adjust preload for front and rear bearings.

   NOTE: At this time, install a pinion height adjusting shim which is temporarily selected or the same as that used before.
   Fig 9: Adjusting Preload For Front & Rear Bearings

   
2. Measure the clearance N between the end of ST3 and the end surface of ST1 by using a thickness gauge.
   NOTE: Make sure there is no clearance between the case and ST3.

   ST1 398507702 DUMMY SHAFT

   ST2 398507703 DUMMY COLLAR

   ST3 398507701 DIFFERENTIAL CARRIER GAUGE

   Fig 10: Measuring Clearance "N" Between End Of ST3 & End Surface Of ST1

   
3. Obtain the thickness of pinion height adjusting shim to be inserted from the following formula, and replace the temporarily installed shim with this one.

   T = To + N - (H x 0.01) - 0.20 (mm)

   Where:

   T = Thickness of pinion height adjusting shim (mm)

   To = Thickness of shim temporarily inserted (mm)

   N = Reading of thickness gauge (mm)

   H = Figure marked on drive pinion head (Example of calculation)

   To = 2.20 + 1.20 = 3.40 mm

   N = 0.23 mm H = +1,

   T = 3.40 + 0.23 - 0.01 - 0.20 = 3.42

   Result: Thickness = 3.42 mm

   Therefore use the shim 383605200.

   Fig 11: Pinion Height Adjusting Shim Chart

   

ST 398177700 INSTALLER

Fig 12: Pressing Rear Bearing Cone Onto Drive Pinion

ST1 398507703 DUMMY COLLAR

ST2 399780104 WEIGHT

ST3 899580100 INSTALLER

Fig 14: Pressing In Front Bearing Cone Into Case

ST1 399780104 WEIGHT

ST2 899580100 INSTALLER

Fig 15: Pressing In Pilot Bearing

ST 498447120 OIL SEAL INSTALLER

Fig 16: Pressing In New Oil Seal

ST1 899874100 INSTALLER

ST2 399780104 WEIGHT

Fig 17: Pressing On Companion Flange

ST 498427200 FLANGE WRENCH

Tightening torque:  181+/-15 N.m (18.5+/-1.5 kg-m, 134+/-11 ft-lb)

Fig 18: Installing Self-Locking Nut

1. Measure the clearance between differential case and the back of side gear.
2. Adjust the clearance as specified by selecting side gear thrust washer.

   Side gear backlash:  0.1 - 0.2 mm (0.004 - 0.008 in)

   Fig 19: Selecting Side Gear Thrust Washer Chart

   
3. Check the condition of rotation after applying oil to the gear tooth surfaces and thrust surfaces.
4. After inserting pinion shaft lock pin into differential case, stake the both sides of the hole to prevent pin from falling off.
5. Install crown gear on differential case.
   CAUTION: Before installing bolts, apply Lock Tite to bolt threads.

   Lock Tite:  THREE BOND 1324 or equivalent

   NOTE: Tighten diagonally while tapping the bolt heads.

   Tightening torque:  103+/-10 N.m (10.5+/-1.0 kg-m, 76+/-7 ft-lb)

   Fig 20: Installing Crown Gear On Differential Case

   

ST 398487700 DRIFT

Fig 21: Pressing Side Bearing Cone Onto Differential Case

1. The driven gear backlash and side bearing preload can be determined by the side bearing shim thickness.
2. Install the differential case assembly into differential carrier in the reverse order of disassembly.
   Fig 22: Installing Differential Case Assembly Into Differential Carrier

   
3. Install side retainer shims and O-rings to the left and right retainers from which they were removed.
   NOTE:

   • Replace broken or cracked O-ring with new one.
   • Replace broken or corroded side retainer shim with new one of same thickness.
     Fig 23: Side Bearing Retainer Shim Chart

     
4. Align arrow marked on differential carrier with that marked on side retainer during installation.
   CAUTION: Be careful that side bearing outer race is not damaged by bearing roller.
   Fig 24: Aligning Arrow Marked On Differential Carrier With Mark On Side Retainer

   
5. Tighten side bearing retainer bolts.
   CAUTION: Before tightening the two side bearing retainer bolts, apply Lock Tite to bolt threads.

   Lock Tite:  THREE BOND 1105 or equivalent

   Tightening torque:  10.3+/-1.5 N.m (1.05+/-0.15 kg-m, 7.6+/-1.1 ft-lb)

   Fig 25: Installing Side Bearing Retainer Bolts

   
6. Measure the crown gear-to-drive pinion backlash.

   Set magnet base on differential carrier. Align contact point of dial gauge with tooth face of crown gear, and move crown gear while holding drive pinion still. Read value indicated on dial gauge.

   Backlash:  0.10 - 0.20 mm (0.0039 - 0.0079 in)

   Fig 26: Measuring Crown Gear-To-Drive Pinion Backlash

   
7. At the same time, measure the turning resistance of drive pinion. Compared with the resistance when differential case is not installed, if the increase of the resistance is not within the specified range, readjust side bearing retainer shims.
   NOTE: If measured backlash is not within specified range, repeat procedure for adjustment of side bearing retainer shims.

   Turning resistance increases:  2.9 - 10.8 N (0.3 - 1.1 kg, 0.7 - 2.4 lb)

Backlash:  0.10 - 0.20 mm (0.0039 - 0.0079 in)

Fig 27: Re-Checking Crown Gear To Pinion Backlash

Limit of runout:  Less than 0.05 mm (0.0020 in)

Fig 28: Checking Crown Gear Runout On Its Back Surface

1. Apply an even coat of red lead on both sides of three or four teeth on the crown gear. Check the contact pattern after rotating crown gear several revolutions back and forth until a definite contact pattern appears on the crown gear.
2. When the contact pattern is incorrect, read-just according to the instructions given in "TOOTH CONTACT PATTERN".

1. Drive pinion height: 

   ST1 398507702 DUMMY SHAFT

   ST2 398507701 DIFFERENTIAL CARRIER GAUGE

   T = To + N - (H x 0.01) - 0.20 (mm)

   Where: 

   T = Thickness of pinion height adjusting shim (mm)

   To = Thickness of shim temporarily inserted (mm)

   N = Reading of thickness gauge (mm)

   H = Figure marked on drive pinion head

   Fig 29: Checking & Adjusting Tooth Contact Of Crown Gear

   
2. Hypoid gear backlash

   Backlash:  0.10 - 0.20 mm (0.0039 - 0.0079 in)

   Fig 30: Measuring Hypoid Gear Backlash

   

   Adjusting direction of drive pinion

   Adjusting direction of crown gear

   Fig 31: Adjusting Tooth Contact Pattern Of Rear Differential Chart

   

Tightening torque:  29+/-5 N.m (3.0+/-0.5 kg-m, 21.7+/-3.6 ft-lb)

Fig 32: Installing Rear Cover