Differential (Service Information): Overview Lexus GS III facelift

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1. INSPECT FRONT DIFFERENTIAL OIL (for 4WD) Stop the vehicle on a level place. Remove the differential filler plug and gasket. Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the inner surface of the differential filler plug opening. NOTE: Excessively large or small amounts of oil may cause trouble. After replacing oil, drive the vehicle and check the oil level. HINT: If necessary, fill the front differential carrier with hypoid gear oil. Check for oil leakage when the oil level is low. Install the differential filler plug and a new gasket. Torque: 39 N*m ( 400 kgf*cm, 29 ft.*lbf)
2. INSPECT REAR DIFFERENTIAL OIL Stop the vehicle on a level place. Using a hexagon wrench (10 mm), remove the differential filler plug and gasket. Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the inner surface of the differential filler plug opening. NOTE: Excessively large or small amounts of oil may cause trouble. After replacing oil, drive the vehicle and check the oil level. HINT: If necessary, fill the rear differential carrier with differential synthetic gear oil. Check for oil leakage when the oil level is low. Using a hexagon wrench (10 mm), install the differential filler plug and a new gasket. Torque: 49 N*m ( 500 kgf*cm, 36 ft.*lbf)
3. ADD FRONT DIFFERENTIAL OIL (for 4WD) Remove the differential filler plug and gasket. Add oil. Capacity 0.65 to 0.75 liter (0.69 to 0.79 US qts, 0.57 to 0.66 Imp. qts) Oil grade Hypoid gear oil API GL-5 or equivalent RECOMMENDED OIL VISCOSITY: Above -18°C (0°F) SAE 90 Below -18°C (0°F) SAE 80W or 80W-90 Check the oil level. Install the differential filler plug and a new gasket. Torque: 39 N*m ( 400 kgf*cm, 29 ft.*lbf) NOTE: After replacing the oil, recheck the oil level after driving.
4. ADD REAR DIFFERENTIAL OIL Using a hexagon wrench (10mm), remove the differential filler plug and gasket. Add oil. Capacity 1.30 to 1.40 liters (1.38 to 1.48 US qts, 1.15 to 1.23 lmp. qts) Oil grade Toyota genuine differential gear oil LT 75W-85 GL-5 or equivalent Check the oil level. Using a hexagon wrench (10mm), install the differential filler plug with a new gasket. Torque: 49 N*m ( 500 kgf*cm, 36 ft.*lbf) NOTE: After replacing the oil, recheck the oil level after driving.

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1. DRAIN FRONT DIFFERENTIAL OIL Remove the differential filler plug and gasket. Remove the differential drain plug and gasket, and drain the oil.
2. REMOVE ENGINE ASSEMBLY Refer to «REMOVAL»(ref-382704-S35045577152011012800000)
3. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY Support the differential carrier with a jack. NOTE: Do not drop the differential carrier. Remove the 3 bolts and differential carrier. NOTE: Do not damage the installation surface when removing the differential carrier assembly. The remaining oil may leak out when removing the differential carrier assembly.

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1. FIX FRONT DIFFERENTIAL CARRIER ASSEMBLY Set the differential carrier to an overhaul stand, etc., as shown in the illustration.
2. INSPECT DIFFERENTIAL RING GEAR BACKLASH Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle. Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand. SST: 09564-32011 Backlash 0.08 to 0.16 mm (0.0031 to 0.0063 in.) If the backlash is not within the specified range, adjust the ring gear backlash or repair as necessary.
3. INSPECT FRONT DRIVE PINION COMPANION FLANGE FRONT Using a dial indicator, measure the runout of the companion flange vertically and horizontally. Maximum runout 0.1 mm (0.0039 in.) If the runout is greater than the maximum value, replace the companion flange.
4. INSPECT TOTAL PRELOAD Using a torque wrench, measure the total preload. Total preload (at starting) 0.78 to 1.27 N*m (8.0 to 13.0 kgf*cm, 6.9 to 11.2 in.*lbf) If the total preload is not within the specified range, adjust the total preload or repair as necessary.
5. REMOVE FRONT DIFFERENTIAL BREATHER PLUG Remove the differential breather plug from the differential carrier.
6. REMOVE FRONT DIFFERENTIAL CASE OIL SEAL Using SST, remove the 2 oil seals from the differential carrier. SST: 09308-00010
7. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT Using SST and a hammer, unstake the staked part of the drive pinion nut. SST: 09930-00010 NOTE: Be sure to use the SST with the tapered surface facing the shaft. Do not grind the tip of the SST with a grinder etc. Completely loosen the staked part of the nut when removing it. Do not damage the threads of the drive pinion. Using SST to hold the flange, remove the drive pinion nut. SST: 09330-00021 SST: 09950-30012 09955-03030 NOTE: Apply grease to the threads and tip of the SST center bolt before use.
8. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT Using SST, remove the companion flange. SST: 09950-30012 09951-03010 09953-03010 09954-03010 09955-03030 09956-03020 NOTE: Apply grease to the threads and tip of the SST center bolt before use.
9. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR HINT: Perform this procedure only when the dust deflector is damaged. Using SST and a press, remove the dust deflector. SST: 09950-00020 SST: 09950-60010 09951-00430
10. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL Using SST, remove the oil seal from the differential carrier. SST: 09308-10010 NOTE: Apply grease to the threads and tip of the SST center bolt before use.
11. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER Remove the drive pinion oil slinger.
12. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING Using SST, remove the inner race of the front drive pinion rear tapered roller bearing from the drive pinion. SST: 09556-22010 NOTE: Apply grease to the threads and tip of the SST center bolt before use.
13. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER Remove the drive pinion bearing spacer.
14. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER Remove the 8 bolts. Using a brass bar and hammer, lightly tap the rib of the side bearing retainer to remove it. Using a scraper and wire brush, clean the seal packing on the differential carrier sub-assembly and side bearing retainer. Completely remove the oil with cleaning solvent.
15. REMOVE FRONT DIFFERENTIAL CASE Remove the differential case from the differential carrier.
16. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR Remove the bolt and differential side bearing retainer deflector.
17. REMOVE DIFFERENTIAL DRIVE PINION
18. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING Using SST and a press, remove the inner race of the front drive pinion front tapered roller bearing from the drive pinion. SST: 09950-00020 HINT: If either the drive pinion or the ring gear is damaged, replace both as a set.
19. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING Using a brass bar and hammer, remove the outer race of the front drive pinion front tapered roller bearing and front adjust shim from the differential carrier assembly. HINT: Set the brass bar onto the concave portion of the differential carrier assembly. Lightly and uniformly tap the bearing and shim to remove them.
20. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING Using SST, remove the outer race of the front drive pinion rear tapered roller bearing from the differential carrier. SST: 09502-12010 SST: 09612-65014 09612-01020 09612-01050 NOTE: Insert the SST into the outer race of the front drive pinion rear tapered roller bearing from the concave portion of the differential carrier assembly and engage the claws. Apply grease to the threads and tip of the SST center bolt before use.
21. REMOVE FRONT DIFFERENTIAL CASE BEARING Using SST and a press, remove the LH outer race of the front differential case bearing and case plate washer from the differential carrier. SST: 09950-60010 09951-00540 SST: 09950-70010 09951-07150 NOTE: Put identification marks on the case bearing outer race to distinguish between the RH side and LH side.
22. REMOVE FRONT DIFFERENTIAL CASE BEARING Using SST and a press, remove the RH outer race of the front differential case bearing and case plate washer from the differential side bearing retainer. SST: 09950-60010 09951-00540 SST: 09950-70010 09951-07150 NOTE: Put identification marks on the case bearing outer race to distinguish between the RH side and LH side.
23. REMOVE DIFFERENTIAL RING GEAR Hold the differential case in a vise between aluminum plates. NOTE: Do not overtighten the vise. Put matchmarks on the ring gear and differential case. Using a screwdriver and a hammer, unstake the 4 lock plates. Remove the 8 ring gear set bolts and 4 lock plates. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
24. REMOVE FRONT DIFFERENTIAL CASE BEARING HINT: Perform this procedure only when replacing the case bearing or differential case. Hold the differential case in a vise between aluminum plates. NOTE: Do not overtighten the vise. Using SST, remove the case bearing inner races LH and RH from the differential case. SST: 09950-60010 09951-00390 SST: 09950-40011 09951-04020 09952-04010 09953-04030 09954-04010 09955-04061 09957-04010 09958-04011 NOTE: Do not deform the bearing cage if the bearing is to be reused. Hook the SST claw from the dent of the differential case to the bearing inner race. Apply grease to the threads and tip of the SST center bolt before use.
25. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN Using a pin punch (3 mm) and hammer, remove the straight pin. Remove the 2 differential pinions. [A] Remove the 2 differential pinion thrust washers. [B] Remove the differential pinion shaft. [C] Remove the 2 side gears. [D] Remove the 2 side gear thrust washers No. 1. [E]
26. INSPECT DIFFERENTIAL PINION AND SIDE GEAR Check that there is no damage to the differential pinion gear and side gear. If the differential pinion gear and/or side gear is damaged, replace them with new ones.
27. INSPECT DIFFERENTIAL CASE Check that there is no damage to the differential case. If the differential case is damaged, replace it.

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1. INSTALL DIFFERENTIAL CASE ASSEMBLY Install the 2 thrust washers No. 1 to the 2 side gears. NOTE: Make sure that there is no dirt or foreign matter on the thrust washer, side gear, etc. before installing them. If replacing either the side gear or pinion, replace them as a set. Apply hypoid gear oil API GL-5 to all sliding and rotating parts. Install the 2 side gears, 2 differential pinion gears, 2 differential pinion thrust washers and differential pinion shaft to the differential case. Differential pinion gears [A] Differential pinion thrust washers [B] Differential pinion shaft [C] Differential side gears [D] Differential side gear thrust washers No. 1 [E] HINT: Align the holes of the differential case and differential pinion shaft.
2. ADJUST DIFFERENTIAL PINION AND SIDE GEAR Hold the differential case in a vise between aluminum plates. NOTE: Do not overtighten the vise. Measure the side gear backlash while holding 1 pinion gear toward the differential case. Backlash 0.05 to 0.20 mm (0.0020 to 0.0079 in.) If the backlash is not within the specified range, install the 2 side gear thrust washers No. 1 of different thicknesses. HINT: Refer to the following table to select the 2 side gear thrust washers No. 1. WASHER THICKNESS Mark Thickness mm (in.) 14 0.93 to 0.97 (0.0366 to 0.0382) 02 0.98 to 1.02 (0.0386 to 0.0402) 15 1.03 to 1.07 (0.0406 to 0.0421) 03 1.08 to 1.12 (0.0425 to 0.0441) 16 1.13 to 1.17 (0.0445 to 0.0461) 04 1.18 to 1.22 (0.0465 to 0.0480) Using a pin punch (3 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft. Using a chisel and a hammer, stake the outside of the differential case pin hole.
3. INSTALL DIFFERENTIAL RING GEAR Clean the contact surfaces of the differential case and ring gear. Heat the ring gear to approximately. 100°C (212°F) in boiling water. WARNING: Use thick gloves to protect hands as the ring gear is hot. Carefully take the ring gear out of the boiling water. Hold the differential case in a vise between aluminum plates. NOTE: Do not overtighten the vise. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case. Align the matchmarks on the ring gear and differential case. Temporarily install 4 new lock plates and the 8 bolts. After the ring gear cools down, tighten the 8 bolts. Torque: 97 N*m ( 985 kgf*cm, 71 ft.*lbf) Using a chisel and a hammer, stake the 4 lock plates. Stake one claw so that it is flush against the flat surface of the bolt. Stake the other claw against the surface of the bolt head to act as a stopper if the bolt start to loosen.
4. INSTALL FRONT DIFFERENTIAL CASE BEARING Using SST and a press, install the case bearing inner race LH to the differential case. SST: 09636-20010 NOTE: Do not apply hypoid gear oil to a new bearing. Do not deform the bearing cage. Set the SST to the center of the differential case. If the bearing is replaced, replace it and the bearing outer race as a set.
5. INSTALL FRONT DIFFERENTIAL CASE BEARING Using SST and a press, install the case bearing inner race RH to the differential case. SST: 09636-20010 SST: 09950-60010 09951-00410 NOTE: Do not apply hypoid gear oil to a new bearing. Do not deform the bearing cage. Set the SST to the center of the differential case. If the bearing is replaced, replace it and the bearing outer race as a set.
6. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING Using SST, the bolt, nut (M12 X P1.25) and washer, install outer race of the rear tapered roller bearing. SST: 09950-60020 09951-00710 09951-00720 NOTE: Do not apply hypoid gear oil to a new bearing. HINT: Bolt: M12 X P1.25, bolt length: 186 mm (09101-12159) Nut: M12 X P1.25 (09101-12159)
7. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING Install the front adjust shim to the differential carrier. Using SST, the bolt, nut (M12 X P1.25) and washer, install outer race of the front tapered roller bearing. SST: 09950-60010 09951-00640 SST: 09950-60020 09951-00810 NOTE: Do not apply hypoid gear oil to a new bearing. HINT: Bolt: M12 X P1.25, bolt length: 186mm (09101-12159) Nut: M12 X P1.25 (90179-12051)
8. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING Using SST and a press, install the inner race of the front drive pinion front tapered roller bearing to the drive pinion. SST: 09506-30012 NOTE: Do not apply hypoid gear oil to a new bearing.
9. INSTALL FRONT DIFFERENTIAL CASE BEARING Install the case plate washer to the differential carrier. Using SST and a press, install the outer race of the front differential case bearing LH to the differential carrier. SST: 09950-60020 09951-00730 NOTE: Do not apply hypoid gear oil to a new bearing.
10. INSTALL FRONT DIFFERENTIAL CASE BEARING Install the case plate washer to the differential side bearing retainer. Using SST and a press, install the outer race of the front differential case bearing RH to the differential side bearing retainer. SST: 09950-60020 09951-00730 NOTE: Do not apply hypoid gear oil to a new bearing.
11. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD Install the drive pinion, inner race of the front drive pinion rear tapered roller bearing and drive pinion oil slinger to the differential carrier. HINT: Assemble the drive pinion bearing spacer and oil seal after adjusting the gear contact pattern. Using SST, install the companion flange. SST: 09950-30012 09951-03010 09953-03010 09954-03010 09955-03030 09956-03020 NOTE: Install the companion flange so that there is slight looseness on the drive pinion because the bearing spacer is not installed. Apply grease to the threads and tip of the SST center bolt before use. Coat the threads of the drive pinion nut with hypoid gear oil LSD. SST: 09330-00021 SST: 09950-30012 09955-03030 Using SST to hold the flange, tighten the drive pinion nut. HINT: Tighten the nut approximately 98 N*m (1,000 kgf*cm, 72 ft.*lbf), and tighten it further while checking the preload. NOTE: Apply hypoid gear oil LSD to the nut and the threads of the drive pinion. As there is no bearing spacer, tighten the nut a little at a time and do not overtighten. Turn the bearing clockwise and counterclockwise several times to stabilize it. Using a torque wrench, measure the preload. Drive pinion preload (at starting) New bearing 0.98 to 1.57 N*m (9.99 to 16.01 kgf*cm, 8.67 to 13.90 in.*lbf) Reused bearing 0.49 to 0.78 N*m (5.00 to 7.95 kgf*cm, 4.34 to 6.90 in.*lbf) NOTE: Record the preload for total preload measurement. Do not apply hypoid gear oil to a new bearing. If the preload is not within the specified range, adjust the differential drive pinion preload or repair as necessary.
12. INSTALL FRONT DIFFERENTIAL CASE Install the differential case to the differential carrier.
13. INSPECT AND ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION Install the differential side bearing retainer with the 8 bolts. Torque: 58 N*m ( 590 kgf*cm, 43 ft.*lbf) Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle. Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand. SST: 09564-32011 Backlash 0.08 to 0.16 mm (0.0031 to 0.0063 in.) HINT: If a new case bearing is used, select a thinner one and install it. If the case bearing is reused, select a case washer with the same thickness as the removed one. WASHER THICKNESS Thickness mm (in.) Thickness mm (in.) Thickness mm (in.) 2.21 to 2.23 (0.0870 to 0.0878) 2.55 to 2.57 (0.1004 to 0.1012) 2.89 to 2.91 (0.1138 to 0.1146) 2.23 to 2.25 (0.0878 to 0.0886) 2.57 to 2.59 (0.1012 to 0.1020) 2.91 to 2.93 (0.1146 to 0.1154) 2.25 to 2.27 (0.0886 to 0.0894) 2.59 to 2.61 (0.1020 to 0.1028) 2.93 to 2.95 (0.1154 to 0.1161) 2.27 to 2.29 (0.0894 to 0.0902) 2.61 to 2.63 (0.1028 to 0.1035) 2.95 to 2.97 (0.1161 to 0.1169) 2.29 to 2.31 (0.0902 to 0.0909) 2.63 to 2.65 (0.1035 to 0.1043) 2.97 to 2.99 (0.1169 to 0.1177) 2.31 to 2.33 (0.0909 to 0.0917) 2.65 to 2.67 (0.1043 to 0.1051) 2.99 to 3.01 (0.1177 to 0.1185) 2.33 to 2.35 (0.0917 to 0.0925) 2.67 to 2.69 (0.1051 to 0.1059) 3.01 to 3.03 (0.1185 to 0.1193) 2.35 to 2.37 (0.0925 to 0.0933) 2.69 to 2.71 (0.1059 to 0.1067) 3.03 to 3.05 (0.1193 to 0.1201) 2.37 to 2.39 (0.0933 to 0.0941) 2.71 to 2.73 (0.1067 to 0.1075) 3.05 to 3.07 (0.1201 to 0.1209) 2.39 to 2.41 (0.0941 to 0.0949) 2.73 to 2.75 (0.1075 to 0.1083) 3.07 to 3.09 (0.1209 to 0.1217) 2.41 to 2.43 (0.0949 to 0.0957) 2.75 to 2.77 (0.1083 to 0.1091) 3.09 to 3.11 (0.1217 to 0.1224) 2.43 to 2.45 (0.0957 to 0.0965) 2.77 to 2.79 (0.1091 to 0.1098) 3.11 to 3.13 (0.1224 to 0.1232) 2.45 to 2.47 (0.0965 to 0.0972) 2.79 to 2.81 (0.1098 to 0.1106) 3.13 to 3.15 (0.1232 to 0.1240) 2.47 to 2.49 (0.0972 to 0.0980) 2.81 to 2.83 (0.1106 to 0.1114) 3.15 to 3.17 (0.1240 to 0.1248) 2.49 to 2.51 (0.0980 to 0.0988) 2.83 to 2.85 (0.1114 to 0.1122) 3.17 to 3.19 (0.1248 to 0.1256) 2.51 to 2.53 (0.0988 to 0.0996) 2.85 to 2.87 (0.1122 to 0.1130) 3.19 to 3.21 (0.1256 to 0.1264) 2.53 to 2.55 (0.0996 to 0.1004) 2.87 to 2.89 (0.1130 to 0.1138) 3.21 to 3.23 (0.1264 to 0.1272) If backlash is not within the specified range, change the thickness of the right and left case washers by equal amounts to adjust it.
14. INSPECT TOTAL PRELOAD Using a torque wrench, measure the total preload. Total preload (at starting) Drive pinion preload plus 0.29 to 0.49 N*m (3.0 to 5.0 kgf*cm, 2.6 to 4.3 in.*lbf) NOTE: If the total preload is not within the specified range, replace the case washer on the ring gear teeth side with another one to adjust it. Do not apply hypoid gear oil to a new bearing.
15. TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Remove the 8 bolts and side bearing retainer. Remove the differential case from the differential carrier. Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead primer. Install the differential case to the differential carrier. Install the differential side bearing retainer with the 8 bolts. Torque: 58 N*m ( 590 kgf*cm, 43 ft.*lbf) Rotate the ring gear in both directions. Remove the 8 bolts and side bearing retainer. Remove the differential case from the differential carrier. Inspect the tooth contact pattern. If the teeth are not contacting properly, use the following table to select a proper plate washer for correction. NOTE: If the contact pattern is either face contact or flank contact, the tooth contact may be adjustable while keeping the backlash within the specified range. If the thickness of the front adjust shim has been changed, adjust the backlash and measure the total preload. WASHER THICKNESS Thickness mm (in.) Thickness mm (in.) Thickness mm (in.) 2.345 to 2.355 (0.0923 to 0.0927) 2.465 to 2.475 (0.0970 to 0.0974) 2.585 to 2.595 (0.1018 to 0.1022) 2.355 to 2.365 (0.0927 to 0.0931) 2.475 to 2.485 (0.0974 to 0.0978) 2.595 to 2.605 (0.1022 to 0.1026) 2.365 to 2.375 (0.0931 to 0.0935) 2.485 to 2.495 (0.0978 to 0.0982) 2.605 to 2.615 (0.1026 to 0.1030) 2.375 to 2.385 (0.0935 to 0.0939) 2.495 to 2.505 (0.0982 to 0.0986) 2.615 to 2.625 (0.1030 to 0.1033) 2.385 to 2.395 (0.0939 to 0.0943) 2.505 to 2.515 (0.0986 to 0.0990) 2.625 to 2.635 (0.1033 to 0.1037) 2.395 to 2.405 (0.0943 to 0.0947) 2.515 to 2.525 (0.0990 to 0.0994) 2.635 to 2.645 (0.1037 to 0.1041) 2.405 to 2.415 (0.0947 to 0.0951) 2.525 to 2.535 (0.0994 to 0.0998) 2.645 to 2.655 (0.1041 to 0.1045) 2.415 to 2.425 (0.0951 to 0.0955) 2.535 to 2.545 (0.0998 to 0.1002) 2.655 to 2.665 (0.1045 to 0.1049) 2.425 to 2.435 (0.0955 to 0.0959) 2.545 to 2.555 (0.1002 to 0.1006) 2.665 to 2.675 (0.1049 to 0.1053) 2.435 to 2.445 (0.0959 to 0.0963) 2.555 to 2.565 (0.1006 to 0.1010) 2.675 to 2.685 (0.1053 to 0.1057) 2.445 to 2.455 (0.0963 to 0.0967) 2.565 to 2.575 (0.1010 to 0.1014) 2.685 to 2.695 (0.1057 to 0.1061) 2.455 to 2.465 (0.0967 to 0.0970) 2.575 to 2.585 (0.1014 to 0.1018) 2.695 to 2.705 (0.1061 to 0.1065)
16. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
17. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT
18. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
19. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
20. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER Install a new drive pinion bearing spacer to the drive pinion. NOTE: Be sure to face the larger inner diameter side rearward as shown in the illustration.
21. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING Using the companion flange, install the inner race of the front drive pinion rear tapered roller bearing to the drive pinion. SST: 09950-30012 09951-03010 09953-03010 09954-03010 09956-03020 09955-03030 NOTE: Apply grease to the threads and tip of the SST center bolt before use. Using SST, remove the companion flange. SST: 09950-30012 09951-03010 09953-03010 09954-03010 09956-03020 09955-03030 NOTE: Apply grease to the threads and tip of the SST center bolt before use.
22. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
23. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL Join the 2 SST and secure them with vinyl tape. SST: 09309-36010 SST: 09502-12010 Using SST and a hammer, install a new oil seal. SST: 09309-36010 SST: 09502-12010 Oil seal drive in depth 0.5 to 1.5 mm (0.020 to 0.059 in.) Apply MP grease to the oil seal lip.
24. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR Install the differential side bearing retainer deflector with the bolt. Torque: 7.0 N*m ( 71 kgf*cm, 62 in.*lbf)
25. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR Using SST and a press, install a new dust deflector. SST: 09316-60011 09316-00011 NOTE: Slowly press in the dust deflector but not excessively. If any burrs remain after pressing in the deflector, remove them.
26. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT Using SST, install the companion flange to the drive pinion. SST: 09950-30012 09951-03010 09953-03010 09954-03010 09955-03030 09956-03020 NOTE: Apply grease to the threads and tip of the SST center bolt before use. Coat the threads of a new drive pinion nut with hypoid gear oil LSD. Using SST to hold the flange, tighten the drive pinion nut. SST: 09330-00021 SST: 09950-30012 09955-03030 Torque: 108 to 235 N*m ( 1100 to 2400 kgf*cm, 80 to 173 ft.*lbf)
27. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD Using a torque wrench, measure the preload of the drive pinion. Preload (at starting) New bearing 0.98 to 1.57 N*m (10.0 to 16.0 kgf*cm, 8.7 to 13.9 in.*lbf) Reused bearing 0.49 to 0.78 N*m (5.0 to 8.0 kgf*cm, 4.3 to 6.9 in.*lbf) If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 10° to adjust it into the specified range. If the preload is less than the specified minimum value even when the tightening torque of the drive pinion nut is greater than the specified maximum value, loosen the nut and check that the threads of the drive pinion nut and drive pinion are not stripped. If the threads are not stripped, replace the bearing spacer. Apply hypoid gear oil LSD to the threads of the drive pinion and repeat the procedure.
28. INSTALL DIFFERENTIAL CASE ASSEMBLY Install the differential case to the differential carrier.
29. APPLICATION SEAL PACKING Check that there are no foreign objects or damage to the installation surface of the side bearing retainer. Apply FIPG to the side bearing retainer. FIPG THREE BOND 1281 or equivalent HINT: Apply FIPG in drops, approximately 1 to 3 mm (0.08 to 0.12 in.) in diameter on the entire surface. Overlap FIPG at least 10 mm (0.39 in.) or more at the beginning and the end of application. Install the carrier cover within 3 minutes after applying FIPG. Do not add oil or drive the vehicle immediately after installing the cover. Leave it for at least an hour. Also, for at least 12 hours, avoid rapid acceleration/deceleration.
30. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER Install the differential side bearing retainer with the 8 bolts. Torque: 58 N*m ( 590 kgf*cm, 43 ft.*lbf)
31. INSTALL FRONT DIFFERENTIAL BREATHER PLUG Install the differential breather plug to the differential carrier. Torque: 21 N*m ( 210 kgf*cm, 15 ft.*lbf)
32. INSPECT TOTAL PRELOAD Using a torque wrench, measure the total preload. Total preload (at starting) Drive pinion preload plus 0.29 to 0.49 N*m (3.0 to 5.0 kgf*cm, 2.6 to 4.3 in.*lbf) If the total preload is not within the specified range, adjust the total preload or repair as necessary.
33. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle. Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand. SST: 09564-32011 Backlash 0.08 to 0.16 mm (0.0031 to 0.0063 in.) If the backlash is not within the specified range, adjust the ring gear backlash or repair as necessary.
34. INSPECT RUNOUT OF FRONT DRIVE PINION COMPANION FLANGE FRONT Using a dial indicator, measure the runout of the companion flange vertically and horizontally. Maximum runout 0.1 mm (0.0039 in.) If the runout is greater than the maximum, replace the companion flange.
35. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT NUT Using a chisel and hammer, stake the drive pinion nut.
36. INSTALL FRONT DIFFERENTIAL CASE OIL SEAL Using SST and a hammer, install 2 new oil seals. SST: 09613-22011 SST: 09950-60010 09951-00560 Oil seal drive in depth 1.0 to 2.0 mm (0.039 to 0.079 in.) (LH Side) 7.5 to 8.5 mm (0.295 to 0.335 in.) (RH Side) Apply MP grease to the oil seal lips.
37. INSTALL FRONT DIFFERENTIAL DRAIN PLUG Install the differential drain plug and a new gasket. Torque: 39 N*m ( 400 kgf*cm, 29 ft.*lbf)
38. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY Remove the differential carrier from the overhaul stand, etc.

See also:
• REMOVAL
• REMOVAL - Step 11
• REMOVAL - Step 3
• REMOVAL - Step 3
• INSTALLATION
• ADJUSTMENT - Step 4