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Differential Assembly: Reassembly

WARNING: This page is about a different car, the 2001 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Steps 1-4 only apply to conventional rear differential models.
  1. Press NEW dust cover on side gear shafts (if removed). Install side gears and thrust washers. Install pinion gears, thrust washers and pinion shaft in differential case. Ensure hole in pinion shaft aligns with hole for straight pin in differential case.
  2. Check side gear backlash with dial indicator. See Figure. Ensure side gear backlash is within .0020-.0079" (.050-.201 mm).
  3. If side gear backlash is not within specification, install different thickness thrust washers on side gears and recheck side gear backlash.
  4. Once correct side gear backlash is obtained, install straight pin in differential case. Using hammer and punch, stake differential case at straight pin area.
  5. On all models, heat ring gear in boiling water. Remove ring gear from water and allow moisture to evaporate. Install ring gear on differential case with reference marks aligned. Temporarily install ring gear bolts to ensure correct alignment of ring gear. Allow ring gear to cool.
    6. CAUTION: Ring gear bolts MUST NOT be tightened to specification until ring gear has cooled.
  6. Once ring gear has cooled, install and tighten ring gear bolts in a crisscross pattern to specification. See TORQUE SPECIFICATIONS . Stake ring gear bolt plates.
  7. Using press, press side bearings on differential case (if removed). Install differential case into carrier. Install 2 plate washers to remove all play in bearings. Install bearing caps. Using a dial indicator, measure ring gear runout. Runout should be .0028" (.071 mm).
  8. Remove bearing caps, plate washers and differential carrier. Press outer races into front and rear of differential carrier. Install original washer onto drive pinion. Press rear bearing onto drive pinion.
  9. Install drive pinion into carrier and install front drive pinion bearing. Check and adjust gear tooth contact pattern. Assemble and install pinion spacer, oil slinger and NEW oil seal.
  10. Press companion flange onto drive pinion. Coat threads of flange nut with grease. Adjusting drive pinion preload by tightening nut, in increments, while holding flange. Tighten nut to reach starting preload of 9.7-14.2 INCH lbs. (1.1-1.7 N.m) if a NEW front bearing was installed, or 5.3-7.9 INCH lbs. (.6-.9 N.m) if original bearing was installed.
    11. CAUTION: When tightening drive pinion nut, DO NOT overtighten nut, as spacer is not installed on drive pinion. Drive pinion nut must be tightened until correct drive pinion rotating torque is obtained.
  11. Install differential case with ring gear and outer bearing races in differential carrier.
  12. Install plate washer on ring gear back side only. Using a plastic hammer, tap on ring gear to snug down washer and bearing. Using dial indicator, check ring gear backlash while rotating ring gear back and forth, and holding drive pinion from rotating. See Figure.
  13. Check ring gear backlash at 3 different areas on ring gear and record ring gear backlash. Ring gear backlash should be .0051" (.129 mm).
  14. If ring gear backlash is not within specifications, select ring gear back side plate washer to bring backlash within specification. Select ring gear teeth side washer thick enough to eliminate any clearance between outer race and differential case.
  15. Remove teeth side plate washer and differential case. Install ring gear back side plate washer. Place outer plate washer onto differential case, together with outer race. Install differential case with outer race into carrier. Tap ring gear with plastic hammer to snug down washer and bearing.
  16. With a dial indicator, re-measure ring gear backlash. It should be .0051-.0071" (.13-.18 mm). If not, increase or decrease thickness of washers on both sides of ring gear by equal amount. Clearance should exist between plate washer and case when backlash is within specification.
  17. When ring gear backlash is properly adjusted, remove teeth side plate washer. With micrometer, measure thickness of plate washer. Install NEW washer that is .0024-.0035" (.060-.088 mm) thicker than plate washer removed. Washer should press into position about 2/3 way by hand. Use brass bar and hammer to fully seat plate washer.
  18. Align reference marks on bearing caps and carrier. Install bearing caps and tighten bolts to specification. See TORQUE SPECIFICATIONS . Ensure ring gear backlash is within specified range. If not, increase or decrease thickness of washers on both sides of ring gear by equal amount.
    19. NOTE: Backlash will change about .0008" (.020 mm) for every .0012" (.030 mm) change in plate washer thickness.
  19. Using INCH-lb. torque wrench installed on drive pinion nut, measure total assembled preload required to rotate drive pinion and ring gear. Total assembled preload should equal amount of starting preload plus 2.6-4.3 INCH lbs. (.3-.5 N.m).
  20. Check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. If gear tooth contact pattern is incorrect, install different thickness adjusting washer located in differential carrier, behind race for front bearing. Recheck gear tooth contact pattern. Adjusting washers are available in various thickness.
  21. Remove companion flange and front bearing. Install NEW spacer on drive pinion. Install NEW front bearing. Install oil slinger on drive pinion. Install drive pinion in differential carrier.
  22. Apply grease to lip of NEW oil seal for drive pinion. Install oil seal in differential carrier until surface of oil seal is .079" (2.01 mm) below surface of differential carrier.
    23. CAUTION: When tightening drive pinion nut, DO NOT overtighten nut. Drive pinion nut must be tightened until correct drive pinion rotating torque is obtained.
  23. Press companion flange onto drive pinion. Coat threads on drive pinion and NEW drive pinion nut with gear oil. Install drive pinion nut. Hold companion flange and tighten nut to 80 ft. lbs. (108 N.m).
  24. Measure preload of backlash between drive pinion and ring gear. Starting preload should be 9.7-14.2 INCH lbs. (1.1-1.7 N.m) with a NEW front bearing, or 5.3-7.9 INCH lbs. (.6-.9 N.m) with a reused bearing.
  25. If drive pinion starting preload exceeds specified range, replace bearing spacer and repeat procedure. If starting preload is less than specified range, tighten drive pinion nut, in small increments, until specified preload is reached. DO NOT exceed 174 ft. lbs. (236 N.m) torque on drive pinion nut. If torque is exceeded, replace spacer and repeat procedure. DO NOT back off nut if torque is exceeded.
  26. Once correct starting preload is obtained, recheck total preload, ring gear backlash, tooth contact pattern between ring gear and drive pinion, and companion flange runout. When okay, stake drive pinion nut. Install NEW side gear oil seals until flush with carrier end surface.
  27. On models equipped with LSD, install NEW snap ring on end of side gear shafts. Coat snap rings with grease. Using slide hammer, install side gear shafts until pinion shaft is contacted.
  28. On models equipped with conventional rear differential, install side gear shafts. Install 2 NEW snap rings into the inside of differential.
  29. Clean carrier and cover contact surfaces. Apply sealant on differential carrier cover and install. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS .
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