Page 2185 of 2389
(d) Check the side gear backlash.
Measure the side gear backlash while holding
one pinion gear toward the case.
Backlash: 0.05 ± 0.20 mm (0.0020 ± 0.079 in.)
If the backlash is not within specification, install the
side gear thrust washers of different thickness.
ASSEMBLY OF DIFFERENTIAL
CARRIER
1. ASSEMBLE DIFFERENTIAL CASE
(a) Install the thrust washers to the side gears.
(b) Install the side gears with thrust washers and pin-
ion gears with thrust washers.
(c) Install the pinion shaft.
HINT: Use washers of same thickness on both the
right and left sides.
(e) Using a hammer and punch, drive in the straight
pin through the case and hole in the pinion shaft.
Thrust washer thickness
(f) Stake the case.mm
(in.)
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±39
Page 2186 of 2389

2. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surface of the differential case.
(b) Heat the ring gear to about 100
°C (2120F) in an oil bath.
NOTICE: Do not heat the ring gear above 110°C (230°F).
(c) Clean the contact surface of the ring gear with cleaning
solvent.
(d) Then quickly install the ring gear on the differential
case.
(e) Align the matchmarks on the ring gear and differential
case.
(f) Coat the ring gear set bolts with gear oil.
(g) Temporarily install the lock plates and set bolts.
(h) After the ring gear cools down enough, tighten the set
bolts uniformly and a little at a time.
Torque: 985 kg±cm (71 ft±Ib, 97 N±m)
4. CHECK RING GEAR RUNOUT
(a) Install the differential case onto the carrier and install
the plate washers to where there is no play in the
bearing (See page RA±42)
(b) Install bearing caps. (See page RA±44)
(c) Using a dial indicator, measure the runout of ring gear.
Maximum runout: 0.07 mm (0.0028 in.) Using a hammer and drift punch, stake the lock
plates.
HINT: Stake one claw flush with the flat surface of
the nut. For the claw contacting the protruding por-
tion of the nut, stake only the half on the tightening
side.
3. INSTALL SIDE BEARINGS
Using a press and SST, drive in the side bearings into
the differential case.
SST 09710±22020 (09710±01030)
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±40
Page 2187 of 2389
7. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the following parts:
w Drive pinion
w Front bearing
HINT: Assemble the spacer, oil slinger and oil seal after
adjusting the gear contact pattern. 6. INSTALL REAR BEARING TO DRIVE PINION
(a) install the plate washer on the drive pinion with the
chamfered end facing toward the pinion gear.
(b) Using a press and SST, install the rear bearing onto the
drive pinion.
SST 09506±30012 5. INSTALL FRONT AND REAR BEARING OUTER RACES
Using a press and SST, drive in the front and rear bear-
ing outer races.
SST 09608±30012
Front (09608±04020 and 09608±00060)
Rear (09608±04020 and 09608±04100)
(c) Adjusting the drive pinion preload by tightening the
companion flange nut.
Using SST to hold the flange, tighten the nut.
SST 09330±00021 (b) Install the companion flange with SST.
SST 09557±22022
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±41
Page 2188 of 2389
(d) Using a torque meter, measure the preload.
Preload (at staring):
New bearing
10 ± 16 kg±cm
(8.7 ± 13.9 in.±Ib, 1.0 ± 1.6 N±m)
Reused bearing
5 ± 8 kg±cm
(4.3 ± 6.9 in.±Ib, 0.5 ± 0.8 N±m)
9. ADJUST RING GEAR BACKLASH
(a) Install only the plate washer on the ring gear back
side.
HINT: Insure that the ring gear has backlash. 8. INSTALL DIFFERENTIAL CASE IN CARRIER
(a)Place the bearing outer races on their respective bear-
ings. Make sure the left and right outer races are not
interchanged.
(b) Install the differential case in the carrier.
(c) Using a dial indicator, measure the backlash.
(d) Select a ring gear back side plate washer so that
the backlash is 0.13 mm (0.0051 in.).
(See table on page RA±44) (b) Snug down the washer and bearing by tapping
on the ring gear with a plastic hammer.
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±42
Page 2189 of 2389
(j) Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 ± 0.18 mm (0.0051 ± 0.0071 in.)
(k) If not within the specification, adjust by either increas-
ing or decreasing the number of washers on both
sides by an equal amount.
HINT: There should be no clearance between the
plate washer and case.
Insure that there is ring gear backlash.(g) Place the other plate washer onto the differential
case together with the outer race, and install the
differential case with the outer race into the car-
rier. (e) Select a ring gear teeth side washer with a thick-
ness which eliminates any clearance between
the outer race and case.
(f) Remove the plate washer and differential case.
Install the plate washer into the ring gear back
side.
(h)Using a plastic hammer, snug down the washer
and bearing by tapping the ring gear.
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±43
Page 2190 of 2389
(e) Recheck the ring gear backlash.
Backlash: 0.13 ± 0.18 mm (0.0051 ± 0.0071 in.)
(f) If not within the standard, adjust by either increasing or de-
creasing the washers on both sides by equal amount.
HINT: The backlash will change about 0.02 mm (0.0008
in.) with 0.03 mm (0.0012 in.) alteration of the side washer.(b) Install a new plate washer of 0.06 ± 0.09 mm
(0.0024 ± 0.0035 in.) thicker than the removed washer.
HINT: Select a washer which can be pressed in 2/3 of the
way by finger.
(c) Using a hammer and SST, tap in the side washer.
SST 09504±22011 10. ADJUST SIDE BEARING PRELOAD
(a) Remove the ring gear teeth side plate washer and
measure the thickness.
(d) Install the side bearing caps.
HINT: Align the matchmarks on the cap and
carrier.
Torque: 800 kg±cm (58 ft±Ib, 78 N±m)
Washer thicknessmm (in.)
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±44
Page 2191 of 2389
12. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Coat 3 or 4 teeth at three different positions on the ring
gear with red lead.
(b) Hold the companion flange firmly and rotate the ring
gear in both directions.
(c) Inspect the tooth contact. 11. MEASURE TOTAL PRELOAD
Using a torque wrench, measure the total preload.
Total preload (at starting):
Add drive pinion preload
3 ± 5 kg±cm (2.6 ± 4.3 in.±Ib, 0.3 ± 0.5 N±m)
If the teeth are not contacting properly, use the following
chart to select a proper washer for correction.
Thicknessmm (in.)
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±45
Page 2192 of 2389
13. REMOVE COMPANION FLANGE
(See step 3 on page RA±35)
14. REMOVE FRONT BEARING
(See step 5 on page RA±36)
15. INSTALL NEW BEARING SPACER AND FRONT
BEARING
(a) Install a new bearing spacer on the drive pinion.
(b) Install the front bearing on the drive pinion.
(b) Install the plate washer.
(c) Coat the threads of a new nut with gear oil.
(d) Using SST to hold the flange, tighten the nut.
SST 09330±00021
Torque: 1,100 kg±cm (80 ft±Ib, 108 N±m)
17. INSTALL NEW OIL SEAL
(a) Using SST, drive in a new oil seal.
SST 09554±22010
Oil seal drive in depth: 2.0 mm (0.079 in.)
(b) Apply MP grease to oil seal lip.
18. INSTALL COMPANION FLANGE
(a) Using SST, install the companion flange on the shaft.
SST 09557±22022 16. INSTALL OIL SLINGER
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±46