Part 2

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

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.

(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.

(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

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.

(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

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

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

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}.

14. Removal of rear drive pinion companion flange RR
15. Removal of rear differential drive pinion oil slinger
16. Removal of rear drive pinion tapered roller bearing FR

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

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}.

21. Removal of rear drive pinion companion flange RR
22. Installation of rear differential carrier oil seal

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

(2) Using the SST, secure the companion flange RR.
SST 18355AA000, 18334AA000

Captions in illustration

(3) Using a socket wrench (30 mm) and a torque wrench, tighten the drive pinion nut while checking the preload.
Limit: T = 338 Nm {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 Nm {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.

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

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.

(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 Nm {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

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

(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: 0.09 mm {0.004 in}
(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: 0.09 mm {0.004 in}

28. Fixation of rear drive pinion nut
(1) Crimp the drive pinion nut using a chisel and a hammer.
29. Installation of rear differential side gear shaft oil seal
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:T=49Nm {500kgf-cm} {1,100.33cm-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:T=8.0Nm {82kgf-cm} {179.83cm-lbf}

32. Installation of rear differential carrier cover
(1) Apply the seal gasket 1281 to the position of the differential carrier cover as shown in the figure.
Captions in illustration

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.

(2) Install the differential carrier cover to the differential carrier with 8 bolts.
Standard value:T=47Nm {479kgf-cm} {1,057.66cm-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:T=21Nm {214kgf-cm} {15.5 ft-lbf}
34. Removal of rear differential carrier ASSY RR
(1) Remove the rear differential carrier ASSY RR from the overhaul stand.