Differential Case Assembly

1. Install differential gears (3), free axle hub (4) and washers (2) to left case (7).
2. Install left case to right case (1) and tighten screws (8).
   Fig 1: Installing Differential Case Components

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3. Put bevel gear (1) on differential case (2) and fasten them with 10 bolts (3) by tightening them to specified torque. Use thread lock cement for 10 bolts (3).
   CAUTION: Use of any other bolts than that specified is prohibited.

   "A":  Thread lock cement 99000-32020

   Tightening torque 

   Drive bevel gear bolt (a):  85 N.m (8.5 kg-m, 61.5 lb-ft)

   Fig 2: Installing Bevel Gear On Differential Case

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4. Press-fit side bearing (1) with special tool and hydraulic press.

   Special tool:  09944-66020

   Fig 3: Press-Fitting Side Bearing

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5. Install actuator (1) to differential case (2).
   NOTE: Note that installing direction is as shown in the figure.
   Fig 4: Installing Actuator To Differential Case

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6. Hold bearing press-fitted in Step 7) with holder and press-fit side bearing on the other side.

Special tool 

1. (G):  09944-66020
2. (H):  09951-16060

Fig 5: Press-Fitting Side Bearing

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Drive Bevel Pinion 

To engage bevel pinion and gear correctly, it is prerequired to install bevel pinion to differential carrier properly by using adjusting shim as described below. Shown in Fig 9 are relative positions of bevel pinion, differential carrier and mounting dummy.

1. Install bevel pinion dummy with bearings into differential carrier and tighten flange nut (1) so that specified bearing preload is obtained.
   NOTE:

   • This installation requires universal joint flange not equipped with groove on flange periphery.
   • This installation requires no spacer or oil seal.
   • Before taking measurement with spring balance (2) or torque wrench (3), check for rotation by hand and apply small amount of oil to bearings.

   Special tool 

   1. (A):  09922-75222
   2. (B):  09926-78311

   Pinion Bearing Preload 

   Pinion bearing preload (a):  0.9 - 1.7 N.m (9.0 - 17.0 kg-cm, 7.8 - 14.7 lb-in)

   Spring measure reading:  1.8 - 3.4 kg (4.0 - 7.5 lb)

   Fig 6: Checking Bearing Preload

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2. Set dial gauge to bevel pinion mounting dummy and make 0 (zero) adjustment on surface plate.
   NOTE:

   • When setting dial gauge to mounting dummy, tighten screw lightly. Be careful not to overtighten it, which will cause damage to dial gauge.
   • With dial gauge set, turn dummy back and force by hand a couple of times and attain accurate 0 (zero) adjustment.
   • It is desirable that short pointer indicates beyond 2 mm when long one is at 0 (zero).

   Special tool 

   (C):  09926-78311

   (D):  09900-20607

   Fig 7: Making 0 (Zero) Adjustment To Bevel Pinion Mounting Dummy On Surface Plate

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3. Place zero-adjusted mounting dummy and dial gauge set on pinion dummy and take measurement between zero position and extended dial gauge measuring tip.
   NOTE:

   • Repeat turning back and force of dummy and measure distance as far as top surface of pinion dummy accurately.
   • When dial gauge measuring tip extends from 0 (zero) position, pointer turns counterclockwise.
   • Measured value may exceed 1 mm. Therefore, it is also necessary to know reading of short pointer.

   Special tool 

   (C):  09926-78311

   (D):  09900-20607

   Fig 8: Using Pinion Mounting Dummy To Measure Between Zero Position & Extended Dial Gauge Measuring Tip

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4. Obtain adjusting shim thickness by using measured value by dial gauge (which represents "c" in figure) in the following equation.

   94 in above equation is "a" + "b" of mounting dummy (special tool) as shown in the figure.

   Special tool 

   1. (A):  09900-20607
   2. (B):  09926-78311
   3. (C):  09922-75222
   Fig 9: Measuring For Pinion Adjusting Shim

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5. Select adjusting shim(s) (2) closest to calculated value from among the following available sizes and put it in place and then press-fit front bearing (1).

   Special tool 

   (E):  09925-18010

   (F):  09927-66010

   Available shim thickness:  1.12, 1.15, 1.18, 1.21, 1.24, 1.27, 1.30 and 0.3 mm (0.044, 0.045, 0.046, 0.048 0.049, 0.050, 0.051 and 0.012 in.)

   Fig 10: Pressing Adjusting Shim & Bearing On Pinion

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6. With new pinion spacer (3) inserted as shown, install rear bearing (5) to differential carrier (4).
   NOTE:

   • Make sure to use new spacer for reinstallation.
   • Apply oil to bearings.
   Fig 11: Installing Pinion Into Differential Carrier

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7. Using special tool and plastic hammer drive oil seal (2) into differential carrier (1) till it becomes flush with carrier end. Then apply grease to oil seal lip.

   Special tool 

   (G):  09951-18210

   "A":  Grease 99000-25010

   Fig 12: Installing Seal Into Differential Carrier

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8. While tightening flange nut gradually with flange holder (special tool) and power wrench (4-10 magnification) (1), set preload of pinion to specification.

Pinion bearing preload:  0.9 - 1.7 N.m (9.0 - 17.0 kg-cm, 7.8 - 14.7 lb-in)

Spring measure reading:  1.8 - 3.4 kg (4.0 - 7.5 lb)

Special tool 

(A):  09922-75222

(H):  09922-66021

Fig 13: Tightening Flange Nut To Set Bearing Preload

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