Rear Differentials: 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 improperly 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 races of the bearings.
- Use a new O-ring and gasket.
- Replace the oil seal with a new one at every disassembly. Apply chassis grease between the lips when installing the oil seal.
- Be careful not to confuse the installing direction of oil seal.
Adjusting preload for front and rear bearings
Adjust the bearing preload with spacer and washer between front and rear bearings. Pinion height adjusting washer are not affected by this adjustment. The adjustment must be carried out without oil seal inserted.
Press the rear bearing race into differential carrier using ST1 and ST2.
ST1 32005061 HANDLE
ST2 32005063 DRIFT 2
Install the front bearing race to differential carrier using ST1 and ST2.
ST1 32005061 HANDLE
ST2 32005063 DRIFT 2
Insert the ST1 into carrier with pinion height adjusting washer and rear bearing cone fitted onto it.
- If tooth contact (Drive pinion, Hypoid driven gear) is normal in the inspection before disassembling, verify that the washer is not deformed, and then re-use the used washer.
- Use a new rear bearing cone.
Then install the preload adjusting spacer and washer, front bearing cone, ST2, companion flange, and washer and drive pinion nut.
ST1 32005067 DUMMY SHAFT
ST2 32005068 DUMMY COLLAR
- Pinion height adjusting washer
- Preload adjusting spacer
- Preload adjusting washer
Turn the ST1 with hand to make it seated, and tighten the self-locking nut while measuring the preload with spring balance. Select the preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque.
- Use a new self-locking nut.
- Be careful not to give excessive preload.
- When tightening the self-locking nut, lock ST1 with ST2 as shown in the figure.
- Measure the preload in direction of tangent to flange.
ST1 32005067 DUMMY SHAFT
ST2 32005069 BLOCK
Tightening torque:
181 Nm (18.5 kgf-m, 134 ft-lb)
| Drive pinion bearing preload |
|---|
| 18.1 - 38.8 N (1.8 - 4.0 kgf, 4.1 - 8.7 lb) at companion flange bolt hole |
| Preload adjusting washer | Part No. | Thickness mm (in) |
| 32007051 | 2.59 (0.1020) | |
| 32007052 | 2.57 (0.1012) | |
| 32007053 | 2.55 (0.1004) | |
| 32007054 | 2.53 (0.0996) | |
| 32007055 | 2.51 (0.0988) | |
| 32007056 | 2.49 (0.0980) | |
| 32007057 | 2.47 (0.0972) | |
| 32007058 | 2.45 (0.0965) | |
| 32007059 | 2.43 (0.0957) | |
| 32007060 | 2.41 (0.0949) | |
| 32007062 | 2.39 (0.0941) | |
| 32007063 | 2.37 (0.0933) | |
| 32007064 | 2.35 (0.0925) | |
| 32007065 | 2.33 (0.0917) | |
| 32007066 | 2.31 (0.0909) | |
| Preload adjusting spacer | Part No. | Length mm (in) |
| 32007045 | 56.2 (2.213) | |
| 32007046 | 56.4 (2.220) | |
| 32007047 | 56.6 (2.228) | |
| 32007048 | 56.8 (2.236) | |
| 32007049 | 57.0 (2.244) | |
| 32007050 | 57.2 (2.252) |
Drive pinion height adjustment
Adjust the drive pinion height with shim installed between the rear bearing cone and back of pinion gear.
Install the ST2.
ST1 32005067 DUMMY SHAFT
ST2 32005066 DIFFERENTIAL CARRIER GAUGE
ST3 32005068 DUMMY COLLAR
- Pinion height adjusting washer
Measure the clearance N between the end of ST2 and end surface of ST1 by using a thickness gauge.
ST1 32005067 DUMMY SHAFT
ST2 32005066 DIFFERENTIAL CARRIER GAUGE
Obtain the thickness of pinion height adjusting washer 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 (0.0079 in)
| T | Thickness of pinion height adjusting shim mm (in) |
| To | Thickness of washer temporarily inserted mm (in) |
| N | Reading of thickness gauge mm (in) |
| H | Figure marked on drive pinion head |
| Memo: | |
(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 washer 32007036.
| Pinion height adjusting washer | |
|---|---|
| Part No. | Thickness mm (in) |
| 32007021 | 3.09 (0.1217) |
| 32007022 | 3.12 (0.1228) |
| 32007023 | 3.15 (0.1240) |
| 32007024 | 3.18 (0.1252) |
| 32007026 | 3.21 (0.1264) |
| 32007028 | 3.24 (0.1276) |
| 32007029 | 3.27 (0.1287) |
| 32007030 | 3.30 (0.1299) |
| 32007031 | 3.33 (0.1311) |
| 32007033 | 3.36 (0.1323) |
| 32007035 | 3.39 (0.1335) |
| 32007036 | 3.42 (0.1346) |
| 32007037 | 3.45 (0.1358) |
| 32007038 | 3.48 (0.1370) |
| 32007039 | 3.51 (0.1382) |
| 32007040 | 3.54 (0.1394) |
| 32007041 | 3.57 (0.1406) |
| 32007042 | 3.60 (0.1417) |
| 32007043 | 3.63 (0.1429) |
| 32007044 | 3.66 (0.1441) |
Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST.
ST 32005054 INSTALLER
Insert the drive pinion into differential carrier, install the previously selected bearing preload adjusting spacer and washer.
- Drive pinion
- Bearing adjusting spacer
- Washer
- Differential carrier
Press-fit the front bearing cone into case with ST1, ST2 and ST3.
ST1 32005068 DUMMY COLLAR
ST2 32005081 WEIGHT
ST3 32005175 INSTALLER
Insert the spacer, then press-fit the pilot bearing with ST1 and ST2.
ST1 32005081 WEIGHT
ST2 32005175 INSTALLER
Fit a new oil seal with ST.
- Press-fit until the end of oil seal is 1 mm (0.04 in) inward from end of carrier.
- Apply grease between the oil seal lips.
ST 32005104 INSTALLER
Press-fit the companion flange with ST1 and ST2.
ST1 32005179 INSTALLER
ST2 32005081 WEIGHT
Install a new self-locking nut. Then tighten it with the ST.
ST 32005101 FLANGE WRENCH
Tightening torque:
181 Nm (18.5 kgf-m, 134 ft-lb)
Assembling differential case
Install the side gears and pinion mate gears, with their thrust washers and pinion mate shaft, into differential case. (Model without LSD)
- Apply gear oil on both sides of the washer and on the side gear shaft before installing.
- Insert the pinion mate shaft into the differential case by aligning the lock pin holes.
Measure the side gear backlash.
Side gear backlash:
0.10 - 0.20 mm (0.0039 - 0.0079 in)
Adjust the backlash as specified by selecting the side gear thrust washer.
| Side gear thrust washer | |
|---|---|
| Part No. | Thickness mm (in) |
| 32007010 | 0.75 - 0.80 (0.0295 - 0.0315) |
| 32007011 | 0.80 - 0.85 (0.0315 - 0.0335) |
| 32007012 | 0.85 - 0.90 (0.0335 - 0.0354) |
Check the condition of rotation after applying oil to the gear tooth surfaces and thrust surfaces.
After inserting the pinion shaft lock pin into differential case, stake both sides of the hole to prevent pin from falling off.
Install the hypoid driven gear on differential case.
Lock Tite:
THREE BOND 1324 (Part No. 32005016) or equivalent
Tightening torque:
105 Nm (10.7 kgf-m, 77.4 ft -lb)
Press the side bearing into differential case using ST.
ST 32005057 DRIFT
Press the side bearing cone into side bearing retainer using ST.
ST 32005064 DRIFT
Adjusting side bearing retainer shims
The driven gear backlash and side bearing preload can be determined by the side bearing retainer shim thickness.
Install the differential case assembly into differential carrier in the reverse order of disassembly.
Install the side retainer shims to the right and left retainers from which they were removed.
| Side bearing retainer shim | |
|---|---|
| Part No. | Thickness mm (in) |
| 32007015 | 0.20 (0.0079) |
| 32007016 | 0.25 (0.0098) |
| 32007017 | 0.30 (0.0118) |
| 32007018 | 0.40 (0.0157) |
| 32007019 | 0.50 (0.0197) |
Align the arrow mark on differential carrier with the mark on side retainer during installation.
- Arrow mark
Tighten the side bearing retainer bolts.
Lock Tite:
THREE BOND 1105 (Part No.32005014) or equivalent
Tightening torque:
10.3 Nm (1.05 kgf-m, 7.6 ft-lb)
Measure the hypoid driven gear-to-drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of hypoid driven gear, and move the hypoid driven gear while holding drive pinion still. Read the value indicated on dial gauge.
Backlash:
0.10 - 0.20 mm (0.0039 - 0.0079 in)
At the same time, measure the total preload of drive pinion. Compared with the resistance when differential case is not installed, if the total preload is not within specification, adjust the thickness of side bearing retainer shims, increasing/reducing by an even amount at a time.
Total preload:
20.7 - 54.4 N (2.1 - 5.5 kgf, 4.7 - 12.2 lb)
Re-check the hypoid driven gear-to-pinion backlash.
Backlash:
0.10 - 0.20 mm (0.0039 - 0.0079 in)
Check the hypoid driven gear runout on its back surface, and make sure that pinion and hypoid driven gear rotate smoothly.
Limit of runout:
Less than 0.05 mm (0.0020 in)
Checking and adjusting tooth contact of hypoid driven gear
Apply an even coat of red lead on both sides of three or four teeth on the hypoid driven gear. Check the contact pattern after rotating the hypoid driven gear several revolutions back and forth until a definite contact pattern appears on the hypoid driven gear.
When the contact pattern is incorrect, readjust according to the instructions given in "TOOTH CONTACT PATTERN".
- Correct tooth contact
Checking item: Tooth contact pattern is slightly shifted toward to toe side under no-load rotation. (When loaded, contact pattern moves toward heel)
- Toe side
- Heel side
- Face contact
Checking item: Backlash is too large.
Contact pattern
- Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring drive pinion close to hypoid driven gear.
- Flank contact
Checking item: Backlash is too small.
Contact pattern
Corrective action: Reduce thickness of drive pinion height adjusting washer in order to move drive pinion away from hypoid driven gear.
- Toe contact (Inside end contact)
Checking item: Contact area is small.
Contact pattern
Corrective action: Reduce thickness of drive pinion height adjusting washer in order to move drive pinion away from hypoid driven gear.
- Heel contact (Outside end contact)
Checking item: Contact area is small.
Contact pattern
Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring drive pinion close to hypoid driven gear.
If proper tooth contact is not obtained, once again adjust the drive pinion height by changing RH and LH side bearing retainer shims and the hypoid gear backlash.
Remove the side bearing retainers on right and left side.
Install new O-rings to side bearing retainers on right and left side.
Install the oil seals to side bearing retainers on right and left side.
Align the arrow mark on differential carrier with the mark on side retainer during installation.
- Arrow mark
Tighten the side bearing retainer bolts.
Lock Tite:
THREE BOND 1105 (Part No. 32005014) or equivalent
Tightening torque:
10.3 Nm (1.05 kgf-m, 7.6 ft-lb)
Install the new gasket and rear cover and tighten the bolts to specified torque.
Tightening torque:
29 Nm (3.0 kgf-m, 21.7 ft -lb)
Install the breather cap.
Install the drain plug and filler plug.
Tightening torque:
49 Nm (5.0 kgf-m, 36.2 ft -lb)