Driveline, Axle = '17 Model

WORKSHOP MANUAL
Differentials
 Differentials 3B-1

Driveline, Axle
Differentials
Table of Contents
Rear differential (single) (17.5H)....................................3B-2
removal.......................................................................3B-2
disassembly.................................................................3B-5
inspection..................................................................3B-12
reassembly................................................................3B-15
installation.................................................................3B-26
Rear differential (single) (18.5H)..................................3B-30
removal.....................................................................3B-30
disassembly...............................................................3B-32
inspection..................................................................3B-39
reassembly................................................................3B-42
installation.................................................................3B-53
Rear differential (tandem)（17.5HT）.........................3B-56
removal.....................................................................3B-56
disassembly...............................................................3B-60
inspection..................................................................3B-72
reassembly................................................................3B-77
installation.................................................................3B-94
Inter axle differential lock shift unit (17.5HT)..............3B-99
removal.....................................................................3B-99
disassembly.............................................................3B-100
inspection................................................................3B-102
reassembly..............................................................3B-104
installation...............................................................3B-107
Differential oil.............................................................3B-109
replacement.............................................................3B-109
Supplementary Information.........................................3B-111
3B-2 Differentials

Rear differential (single) (17.5H)

removal 1. Component views

Rear differential (Single)

Part name
1. Filler plug
2. Drain plug
3. Final drive

Tightening torque
1: 69 N・m { 7.0 kgf・m / 51 lb・ft }
2: 69 N・m { 7.0 kgf・m / 51 lb・ft }
3: 219 N・m { 22.3 kgf・m / 162 lb・ft }
2. Preliminary and post procedures
1. Preliminary procedures
1) Raise the vehicle.
3. Differential oil drain
1) Remove the filler plug from the rear axle case.
1) Remove the propeller shaft guard from the vehicle
2) Remove the drain plug from the rear axle case, and
if one exists.
drain the differential oil.
2) Remove the propeller shaft from vehicle.
Caution：
・ Do not reuse the O-ring. Note：
・ Remove in order starting from the rear of the
4. Propeller shaft removal
vehicle and moving forward.
Caution：
・ Because the propeller shaft is adjusted to have
a precise balance, always place an alignment
mark on each of the joints before removing,
disassembling, etc.
 Differentials 3B-3

Axle flange Transmission flange

Center bearing flange (Propeller shaft with center 5. Propeller shaft between tandem axles removal
bearing) 1. FVZ
Caution：
・ Because the propeller shaft is adjusted to have
a precise balance, always place an alignment
mark for each of the joints before removing,
disassembling, etc.
1) Remove the propeller shaft between the axles from
the vehicle.
Caution：
・ Remove the needle bearing while taking care
not to drop it.

6. Rear axle shaft removal

1) Move the vehicle to a flat surface.
2) Pull the parking brake lever.
3B-4 Differentials
3) Secure the vehicle using chock blocks.
4) Remove the rear axle shaft from the rear axle.
7. Final drive removal
1) Remove the bolts from the differential carrier.
2) Install the bolts to the replace bolt holes of the
differential carrier, and pull out the final drive from
the rear axle case.

3) Use a differential jack or transmission jack to

remove the final drive from the rear axle case.
 Differentials 3B-5

disassembly 1. Component views

Rear final drive (Single) (17.5H, 18.5H)

Part name 13. Lock washer (Except 18.5H)

14. Adjust nut
1. Drive pinion
15. Side bearing
2. Retainer
16. Differential cage
3. Pilot bearing
4. Retainer Tightening torque
5. Snap ring
6. Cotter pin 1: 402 N・m { 41.0 kgf・m / 296 lb・ft }
7. Shim 2: 20 N・m { 2.0 kgf・m / 15 lb・ft } 17.5H
8. Differential carrier
9. Adjust nut 3: 13 N・m { 1.3 kgf・m / 115 lb・in }
10. Side bearing 4: 185 N・m { 18.9 kgf・m / 136 lb・ft }
11. Bearing cap
12. Lock plate
3B-6 Differentials

Rear drive pinion (Single) (17.5H, 18.5H)

Part name 8. Pinion cage

9. Inner bearing
1. Flange nut
10. Drive pinion
2. O-ring
11. Pilot bearing
3. Flange
12. Snap ring
4. Oil seal
5. Outer bearing Tightening torque
6. Spacer
7. Shim 1: 834 N・m { 85.0 kgf・m / 615 lb・ft }
 Differentials 3B-7

Rear differential cage (Single) (17.5H, 18.5H)

Part name
1. Differential cage A
2. Side gear thrust washer
3. Side gear
4. Pinion gear thrust washer
5. Pinion gear
6. Side gear
7. Side gear thrust washer
8. Spider
9. Differential cage B and ring gear

Tightening torque
1: 206 N・m { 21.0 kgf・m / 152 lb・ft }
2: 431 N・m { 43.9 kgf・m / 318 lb・ft }
2. Final drive disassembly
1) Remove the drive pinion and shim from the
differential carrier. 2) Place alignment marks on the adjust nut and bearing
cap.
Caution：
・ When removing the drive pinion, make sure
not to damage the shim.
3B-8 Differentials

1. Alignment mark 1. Alignment mark

3) Remove the lock washer and lock plate from the 5) Remove the bearing cap from the differential
bearing cap. carrier.
Note：
・ Put tags, etc. on the removed bearing caps,
adjust nuts, bearing outer races, etc., to
identify that they are for the right or left side.

1. Lock washer
2. Lock plate

4) Place alignment marks on the bearing cap and

differential carrier.
6) Remove the differential cage from the differential
carrier.
Note：
・ At this time, remove the differential cage by
pulling it to the ring gear side to prevent it from
getting caught on the pilot bearing section.
 Differentials 3B-9
・ Pilot bearing outer race

7) Apply right and left identification marks to the side

bearing inner race. 1. Pilot bearing outer race
8) Remove the side bearing inner race from the
3. Drive pinion disassembly
differential cage using the special tool.
1) Pry up the stake of the flange nut using a punch.

SST: 9-8521-0131-0 - bearing remover

2) Remove the flange nut from the drive pinion using

special tool.

9) Remove the cotter pin from the retainer bolt.

10) Remove the following parts from the differential
SST: 9-8522-1243-1 - spline yoke bracket
carrier.
・ Retainer
・ Bolt
・ Nut
3B-10 Differentials

3) Remove the following parts from the drive pinion 1. Snap ring
by tapping the rear of the drive pinion lightly with a 2. 1-8521-9009-0
copper hammer or brass rod.
8) Remove the pilot bearing inner race using the
・ Flange special tool.
・ O-ring
・ Pinion cage
・ Shim
・ Spacer
4) Remove the oil seal from the pinion cage.
5) Remove the outer bearing inner race and outer
bearing outer race from the pinion cage.
6) Remove the inner bearing outer race from the SST: 9-8521-0182-0 - bearing remover
pinion cage.
7) Push the snap ring into the snap ring groove using
the special tool.

SST: 1-8521-9009-0 - pilot bearing remover

9) Remove the inner bearing inner race from the drive

pinion using the special tool.
 Differentials 3B-11
3) Remove the side gear and side gear thrust washer
from differential cage A.
4) Remove the following parts from differential cage
B.
・ Spider
・ Pinion gear
・ Pinion gear thrust washer
SST: 9-8521-0152-0 - bearing remover
・ Side gear
・ Side gear thrust washer

4. Differential cage disassembly

1) Apply alignment marks to differential cage A and 1. Side gear
differential cage B. 2. Pinion gear

5) Remove the ring gear from differential cage B.

Caution：
・ Because LOCTITE is used for the tightening
bolt of the ring gear, do not remove the ring
gear tightening bolt for any reason other than
ring gear replacement.

1. Alignment mark

2) Remove differential cage A from differential cage

B.
Caution：
・ Do not reuse the differential cage bolts and
nuts.
3B-12 Differentials

inspection
1. Final drive inspection
1) Inspect each bearing for the following.
・ Excessive play, spalling, wear, and damage of the
inner race, outer race, and roller
・ Abnormal feeling when rotated by hand

Caution：
・ Replace the drive pinion with the ring gear as
a set.
3) Inspect each bearing for the following.
・ Excessive play, spalling, wear, and damage
・ Abnormal feeling when rotated by hand

2. Drive pinion inspection

1) Inspect the drive pinion for the following.
・ Wear
・ Damage
・ Pitching
Caution：
・ Replace the drive pinion with the ring gear as
a set.
2) Inspect the drive pinion tooth surface for the
following.
・ Wear
・ Damage
・ Pitching

3. Differential cage inspection

1. Visual inspection
1) Inspect the side gear tooth surface for the following.
・ Wear
・ Damage
・ Pitching
 Differentials 3B-13

2) Inspect the side gear thrust washer for the Caution：

following. ・ Replace the ring gear with the drive pinion as
・ Significant wear a set.
・ Damage 2. Measurement of clearance between the differential
3) Inspect the pinion gear tooth surface for the cage and side gear
following.
1) Measure the inner diameter of the differential cage.
・ Tooth surface and inner surface wear
2) Measure the outer diameter of the side gear.
・ Tooth surface and inner surface damage
・ Tooth surface pitting 3) Calculate the clearance size from the measured
value.
Clearance between the differential cage and the side
gear
Standard value Limit
0.18 to 0.25 mm { 0.0071
0.5 mm { 0.0197 in }
to 0.0098 in }

4) Inspect the pinion gear thrust washer for the

following.
・ Significant wear
・ Damage
5) Inspect the ring gear for the following.
・ Wear
・ Damage 3. Measurement of play of the side gear spline in the
・ Pitching rotational direction
1) Insert the axle shaft into the side gear.
3B-14 Differentials
2) Measure the play of the side gear spline in the 1) Measure the pinion gear thrust washer thickness.
rotational direction.
Pinion gear thrust washer thickness
Play of the spline in the rotational direction Standard value Limit
Standard value Limit 1.6 mm { 0.063 in } 1.5 mm { 0.059 in }
0.2 mm or less { 0.0079 in
0.5 mm { 0.0197 in }
or less }

4. Measurement of clearance between the spider and

the pinion gear
1) Measure the outer diameter of the spider.
2) Measure the inner diameter of the pinion gear.
3) Calculate the clearance size from the measured
value.
Clearance between the spider and the pinion gear
Standard value Limit
0.06 to 0.15 mm { 0.0024
0.3 mm { 0.0118 in }
to 0.0059 in }

5. Measurement of pinion gear thrust washer thickness

 Differentials 3B-15

reassembly 1. Component views

Rear final drive (Single) (17.5H, 18.5H)

Part name 13. Lock washer (Except 18.5H)

14. Adjust nut
1. Drive pinion
15. Side bearing
2. Retainer
16. Differential cage
3. Pilot bearing
4. Retainer Tightening torque
5. Snap ring
6. Cotter pin 1: 402 N・m { 41.0 kgf・m / 296 lb・ft }
7. Shim 2: 20 N・m { 2.0 kgf・m / 15 lb・ft } 17.5H
8. Differential carrier
9. Adjust nut 3: 13 N・m { 1.3 kgf・m / 115 lb・in }
10. Side bearing 4: 185 N・m { 18.9 kgf・m / 136 lb・ft }
11. Bearing cap
12. Lock plate
3B-16 Differentials

Rear drive pinion (Single) (17.5H, 18.5H)

Part name 8. Pinion cage

9. Inner bearing
1. Flange nut
10. Drive pinion
2. O-ring
11. Pilot bearing
3. Flange
12. Snap ring
4. Oil seal
5. Outer bearing Tightening torque
6. Spacer
7. Shim 1: 834 N・m { 85.0 kgf・m / 615 lb・ft }
 Differentials 3B-17

Rear differential cage (Single) (17.5H, 18.5H)

Part name 2) Install the ring gear to differential cage B.

1. Differential cage A Tightening torque: 431 N・m { 43.9 kgf・m / 318 lb・
2. Side gear thrust washer ft }
3. Side gear
4. Pinion gear thrust washer
5. Pinion gear
6. Side gear
7. Side gear thrust washer
8. Spider
9. Differential cage B and ring gear

Tightening torque
1: 206 N・m { 21.0 kgf・m / 152 lb・ft }
2: 431 N・m { 43.9 kgf・m / 318 lb・ft }
2. Final drive safety information
When assembling, if nothing in particular is specified,
refer to the following and apply or add differential oil.
Refer to "[Link] Information [Link]
Information Recommended fluids, lubricants and diesel
fuels". 1. Bolt
3. Differential cage reassembly
3) Apply differential oil to the following parts.
1) Apply LOCTITE 271 or equivalent to the threaded
portion of the bolt. ・ Side gear thrust washer
・ Side gear
3B-18 Differentials
・ Spider
・ Pinion gear
・ Pinion gear thrust washer
4) Install the side gear thrust washer and side gear to
differential cage A.
5) Install the following parts to differential cage B.
・ Side gear thrust washer
・ Side gear
・ Spider
・ Pinion gear
・ Pinion gear thrust washer

1. Alignment mark

7) Measure the gap of the side gear.

Side gear clearance
Standard value
0.23 to 0.32 mm { 0.0091 to 0.0126 in }

1. Side gear
2. Pinion gear

6) Temporarily tighten differential cage A to

differential cage B.
Note：
・ Install according to the alignment marks
applied during disassembly.
Caution：
・ Do not reuse the nuts or bolts.
Tightening torque: 98 N・m { 10.0 kgf・m / 72 lb・ft }
Caution：
・ If the side gear clearance is not within the
specified range, replace the side gear thrust
washer and adjust.
Thickness of the applicable side gear thrust washer
2.8 mm { 0.1102 in }
2.9 mm { 0.1142 in }
3.0 mm { 0.1181 in }
3.1 mm { 0.1220 in }
3.2 mm { 0.1260 in }
3.3 mm { 0.1299 in }
3.4 mm { 0.1339 in }
 Differentials 3B-19
8) Final tighten differential cage A to differential cage
B.
Tightening torque: 206 N・m { 21.0 kgf・m / 152 lb・
ft }
9) Stake the nuts in 2 places.

1. Inner race

4) Install the inner bearing outer race to the pinion

cage.
5) Install the outer bearing outer race to the pinion
cage.
4. Drive pinion reassembly 6) Temporarily tighten the following parts to the drive
1) Install the inner bearing to the drive pinion using pinion using the special tool.
the press. ・ Pinion cage
・ Shim
・ Spacer
・ Outer bearing
・ Flange

SST: 9-8522-1243-1 - spline yoke bracket

Tightening torque: 834 N・m { 85.0 kgf・m / 615 lb・
ft }

2) Install the snap ring to the snap ring groove of the

drive pinion.
3) Install the inner race of the pilot bearing to the drive
pinion using a copper hammer or brass rod, etc.
Note：
・ Set the more heavily chamfered side of the
inner race to the drive pinion side.
3B-20 Differentials

8.6 mm { 0.3386 in }
8.8 mm { 0.3465 in }
9.0 mm { 0.3543 in }
Applicable shim
3.25 mm { 0.1280 in }
3.26 mm { 0.1283 in }
3.27 mm { 0.1287 in }
3.28 mm { 0.1291 in }
3.29 mm { 0.1295 in }
3.30 mm { 0.1299 in }
3.31 mm { 0.1303 in }
3.32 mm { 0.1307 in }
3.33 mm { 0.1311 in }
3.34 mm { 0.1315 in }
3.35 mm { 0.1319 in }
7) Hook the spring scale onto the bolt hole of the 9) Remove the nut and flange from the pinion cage.
pinion cage.
10) Apply LOCTITE 242 or equivalent to the outer
8) Pull the spring scale in the tangential direction and circumference of the oil seal.
measure the preload of the pinion cage.
11) Apply chassis type grease to the lip section of the
Preload of the pinion cage oil seal.
Standard value
35.3 to 45.1 N { 3.6 to 4.6 kg / 7.9 to 10.1 lb }

1. Outer circumference of the oil seal

2. Lip section of the oil seal
Caution：
12) Apply chassis type grease to the O-ring.
・ When the measured preload is outside the
specified range, make adjustments using the 13) Install the oil seal to the flange.
spacer and shim. 14) Install the O-ring to the pinion cage.
Applicable spacer 15) Install the nut and flange to the pinion cage.
7.6 mm { 0.2992 in }
Tightening torque: 834 N・m { 85.0 kgf・m / 615 lb・
7.8 mm { 0.3071 in }
ft }
8.0 mm { 0.3150 in }
8.2 mm { 0.3228 in }
8.4 mm { 0.3307 in }
 Differentials 3B-21

16) Stake the nuts in 2 places. 5) Install the differential cage to the differential
carrier.
Note：
・ Stake so that firm contact is made with the 6) Install the bearing cap, side bearing outer race, and
groove surface on the tightening direction side. adjust nut to the differential carrier.

5. Final drive reassembly Note：

・ Install according to the alignment marks
1) Install the pilot bearing outer race to the differential
applied during disassembly.
carrier, with the snap ring side set to the bearing cap
side.

1. Alignment mark
1. Snap ring 7) Tighten the adjust nut according to the alignment
marks applied during disassembly.
2) Install the retainer to the differential carrier.
Tightening torque: 13 N・m { 1.3 kgf・m / 115 lb・in }
3) Apply a detent to the cotter pin.
4) Install the side bearing inner race to the differential
cage using a brass rod, etc.
3B-22 Differentials
Ring gear runout
Standard value Limit
0.13 mm or less { 0.0051
0.2 mm { 0.0079 in }
in or less }
Caution：
・ When the measured runout is more than the
limit, repair or replace the ring gear or the side
bearing.

1. Alignment mark

8) Temporarily tighten the bearing cap bolt to the

differential carrier.
Tightening torque: 49 N・m { 5.0 kgf・m / 36 lb・ft }
9) Hook the spring scale onto the tightening bolt of the
ring gear.
10) Pull the spring scale in the tangential direction, and
measure the preload of the side bearing. 12) Temporarily tighten the drive pinion and shim to
Side bearing preload the differential carrier.
Standard value Note：
24.5 to 49.0 N { 2.5 to 5.0 kg / 5.5 to 11.0 lb } ・ Install by aligning with the oil hole of the
differential carrier.
Caution：
・ Do not apply liquid gasket at this point.
Tightening torque: 186 N・m { 19.0 kgf・m / 137 lb・
ft }

Caution：
・ When the measured preload is outside the
specified range, make adjustments with the
adjust nut.
11) Measure the runout of the ring gear using the dial
gauge.
 Differentials 3B-23
1. Oil hole 18) Gently move the ring gear back and forth while
2. Shim holding the drive pinion by hand, and inspect the
tooth contact of the ring gear and drive pinion.
13) Secure the dial gauge stand to the flange surface of
the differential carrier.
14) Apply the gauge head of the dial gauge to the rear
surface of the ring gear, and set the long needle of
the dial gauge to 0.
15) Gently move the ring gear back and forth while
pressing the drive pinion by hand, then measure the
backlash of the ring gear and drive pinion.
Backlash
Standard value
0.3 to 0.4 mm { 0.0110 to 0.0142 in }

19) Correct contact is 70% of the full length of the gear

centered on the pitch line, towards the heel side
(outer side), and leaving approximately 5.0 mm
{0.20 in} to the toe side (inner side).

Caution：
・ When the measured backlash is outside the
specified range, adjust the position of the
differential cage with the adjust nut.
Note：
・ At this time, to prevent a change in preload of
the side bearing, tighten an adjust nut to the
same degree as the other adjust nut was
loosened.
16) Clean the gear teeth of the ring gear and of the drive Caution：
pinion. ・ Refer to the following diagram to adjust the
positions of the ring gear and drive pinion if the
17) Apply red lead primer to the gear teeth of the ring tooth contact of the ring gear and drive pinion
gear. is found to be incorrect as a result of the
Note： inspection.
・ Apply to both surfaces of 7 to 8 gear teeth.
3B-24 Differentials

20) Apply LOCTITE 242 or equivalent to the pinion

cage, differential carrier, and between the shims.

1. Between the shims

 Differentials 3B-25
21) Install the pinion cage to the differential carrier.
Tightening torque: 186 N・m { 19.0 kgf・m / 137 lb・
ft }
22) Final tighten the bearing cap bolt to the differential
carrier.
Tightening torque: 402 N・m { 41.0 kgf・m / 296 lb・
ft }

23) Align the lock plate and lock washer with the adjust
nut groove to install.
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

1. Lock washer
2. Lock plate

24) Detent the adjust bolt by bending the lock washer.

3B-26 Differentials

installation 1. Component views

Rear differential (Single)

Part name
1. Filler plug
2. Drain plug
3. Final drive

Tightening torque
1: 69 N・m { 7.0 kgf・m / 51 lb・ft }
2: 69 N・m { 7.0 kgf・m / 51 lb・ft }
3: 219 N・m { 22.3 kgf・m / 162 lb・ft }
2. Final drive installation
1) Clean the bolts and the rear axle case.
Note：
・ Clean any LOCTITE remaining on the re-used
bolts and the screw holes.
・ Clean the bolts with the die and the screw hole
1. Bolt hole
with the tap as necessary.
2. Rear axle case differential carrier installation
2) Apply LOCTITE 242 or equivalent to the threaded surface
portion of the bolt.
4) Install the final drive to the rear axle case.
3) Apply LOCTITE FMD127 or equivalent to the rear
axle case differential carrier installation surface. Tightening torque: 219 N・m { 22.3 kgf・m / 162 lb・
ft }
3. Rear axle shaft installation
1) Install the rear axle shaft to the rear axle.
Tightening torque: 182 N・m { 18.6 kgf・m / 134 lb・
ft }
 Differentials 3B-27

4. Propeller shaft between tandem axles installation 2) Install the propeller shaft to vehicle.
1. FVZ Note：
Caution： ・ Install in order starting from the front of the
vehicle and moving rearward.
・ Install according to the alignment marks
placed during removal. ・ When installing the center bearing assembly,
temporarily tighten to the vehicle, and then
1) Clean the mounting surfaces of the flange yoke and final tighten after adjusting the center bearing
flange. assembly mounting section so that it is level
Caution： with the frame using the oblong holes.
・ Do not allow foreign material such as grease, ・ If the center bearing assembly mounting bolts
oil, or paint to attach to the installation and nuts of P90HS are M16 x 1.5, install the
surfaces. cotter pins to the nuts.
2) Install the propeller shaft between the axles to the ・ When installing the cotter pin, if the nut groove
vehicle. and hole do not align, tighten further and align
at an angle of 30° or less.
Tightening torque: 103 N・m { 10.5 kgf・m / 76 lb・ft }
206 N・m { 21.0
3) If the needle bearing is secured using wires when Transmission flange
kgf・m / 152 lb・ft }
assembling, remove the wires from the spider.
186 N・m { 19.0
Center bearing
5. Propeller shaft installation kgf・m / 137 lb・ft }
Caution： 206 N・m { 21.0
Center bearing flange
kgf・m / 152 lb・ft }
・ Install according to the alignment marks
206 N・m { 21.0
placed during removal. Axle flange
kgf・m / 152 lb・ft }
1) Clean the flange yoke and flange installation
surfaces so that no grease, oil, paint, or other
foreign material is present.
3B-28 Differentials

Transmission flange Center bearing flange (Propeller shaft with center

bearing)

Center bearing (Propeller shaft with center bearing)

Axle flange

3) Lubricate the propeller shaft.

4) Install the propeller shaft guard to the vehicle if one
exists.
Tightening torque: 48 N・m { 4.9 kgf・m / 35 lb・ft }
6. Differential oil filling
1. Differential oil amount and brand
For the differential oil refill amount, refer to the
following.
Refer to "[Link], Axle [Link]
Information Primary specifications of driveline, axle".
For the differential oil brand, refer to the following.
Refer to "[Link] Information [Link]
Information Recommended fluids, lubricants and diesel
fuels".
 Differentials 3B-29
2. Differential oil refill procedure (Rear differential
[single])
1) Install the drain plug to the rear axle case.
Tightening torque: 69 N・m { 7.0 kgf・m / 51 lb・ft }
2) Add differential oil to the rear axle case.

1. Filler plug hole

3) Install the filler plug to the rear axle case.

Tightening torque: 69 N・m { 7.0 kgf・m / 51 lb・ft }
7. Preliminary and post procedures
1. Post procedures
1) Lower the vehicle.
3B-30 Differentials

Rear differential (single) (18.5H)

removal 1. Component views

Rear differential (Single)

Part name
1. Filler plug
2. Drain plug
3. Final drive

Tightening torque
1: 69 N・m { 7.0 kgf・m / 51 lb・ft }
2: 69 N・m { 7.0 kgf・m / 51 lb・ft }
3: 219 N・m { 22.3 kgf・m / 162 lb・ft }
2. Preliminary and post procedures
1. Preliminary procedures
1) Raise the vehicle.
3. Differential oil drain
1) Remove the filler plug from the rear axle case.
1) Remove the propeller shaft guard from the vehicle
2) Remove the drain plug from the rear axle case, and
if one exists.
drain the differential oil.
2) Remove the propeller shaft from vehicle.
Caution：
・ Do not reuse the O-ring. Note：
・ Remove in order starting from the rear of the
4. Propeller shaft removal
vehicle and moving forward.
Caution：
・ Because the propeller shaft is adjusted to have
a precise balance, always place an alignment
mark on each of the joints before removing,
disassembling, etc.
 Differentials 3B-31

Axle flange Transmission flange

Center bearing flange (Propeller shaft with center 5. Rear axle shaft removal
bearing) 1. Axle shaft type
1) Remove the rear axle shaft from the rear axle.
6. Final drive removal
1) Remove the bolts from the differential carrier.
2) Install the bolts to the replace bolt holes of the
differential carrier, and pull out the final drive from
the rear axle case.

3) Use a differential jack or transmission jack to

remove the final drive from the rear axle case.
3B-32 Differentials

disassembly 1. Component views

Rear final drive (Single) (17.5H, 18.5H)

Part name 13. Lock washer (Except 18.5H)

14. Adjust nut
1. Drive pinion
15. Side bearing
2. Retainer
16. Differential cage
3. Pilot bearing
4. Retainer Tightening torque
5. Snap ring
6. Cotter pin 1: 402 N・m { 41.0 kgf・m / 296 lb・ft }
7. Shim 2: 20 N・m { 2.0 kgf・m / 15 lb・ft } 17.5H
8. Differential carrier
9. Adjust nut 2: 26 N・m { 2.7 kgf・m / 19 lb・ft } 18.5H
10. Side bearing 3: 13 N・m { 1.3 kgf・m / 115 lb・in }
11. Bearing cap
12. Lock plate 4: 185 N・m { 18.9 kgf・m / 136 lb・ft }
 Differentials 3B-33

Rear drive pinion (Single) (17.5H, 18.5H)

Part name 8. Pinion cage

9. Inner bearing
1. Flange nut
10. Drive pinion
2. O-ring
11. Pilot bearing
3. Flange
12. Snap ring
4. Oil seal
5. Outer bearing Tightening torque
6. Spacer
7. Shim 1: 834 N・m { 85.0 kgf・m / 615 lb・ft }
3B-34 Differentials

Rear differential cage (Single) (17.5H, 18.5H)

Part name
1. Differential cage A
2. Side gear thrust washer
3. Side gear
4. Pinion gear thrust washer
5. Pinion gear
6. Side gear
7. Side gear thrust washer
8. Spider
9. Differential cage B and ring gear

Tightening torque
1: 206 N・m { 21.0 kgf・m / 152 lb・ft }
2: 431 N・m { 43.9 kgf・m / 318 lb・ft }
2. Final drive disassembly
1) Remove the drive pinion and shim from the
differential carrier. 2) Place alignment marks on the adjust nut and bearing
cap.
Caution：
・ When removing the drive pinion, make sure
not to damage the shim.
 Differentials 3B-35

1. Alignment mark 8) Remove the differential cage from the differential

carrier.
3) Remove the lock plate from the bearing cap.
Note：
4) Place alignment marks on the bearing cap and
・ At this time, remove the differential cage by
differential carrier.
pulling it to the ring gear side to prevent it from
getting caught on the pilot bearing section.

1. Alignment mark

5) Remove the bearing cap from the differential 9) Apply right and left identification marks to the side
carrier. bearing inner race.

6) Remove the adjust nut from the differential carrier. 10) Remove the side bearing inner race from the
differential cage using the special tool.
7) Remove the side bearing outer race from the
differential carrier.
Note：
・ Put tags on the removed bearing caps, adjust
nuts, side bearing outer races, etc., to identify
that they are for the right or left side.

SST: 9-8521-0131-0 - bearing remover

3B-36 Differentials
11) Remove the cotter pin from the retainer bolt.
12) Remove the following parts from the differential
carrier.
・ Retainer
・ Bolt
・ Nut
・ Pilot bearing outer race
SST: 9-8522-1243-1 - spline yoke bracket

1. Pilot bearing outer race

3) Remove the following parts by tapping the rear of
3. Drive pinion disassembly the drive pinion lightly with a copper hammer or
brass rod, etc.
1) Pry up the stake of the flange nut using a punch.
・ Flange
・ O-ring
・ Pinion cage
・ Shim
・ Spacer
4) Remove the oil seal from the pinion cage.
5) Remove the outer bearing inner race from the
pinion cage.
6) Remove the outer bearing outer race from the
pinion cage.
7) Remove the inner bearing outer race from the
pinion cage.
8) Remove the snap ring from the drive pinion using
the snap ring pliers.

2) Remove the flange nut from the drive pinion using

special tool.
 Differentials 3B-37

1. Snap ring 1. Alignment mark

9) Remove the pilot bearing inner race from the drive 2) Pry up the stake of the nut using the punch.
pinion.
3) Remove differential cage A from differential cage
10) Remove the inner bearing inner race from the drive B.
pinion using the special tool.
Caution：
・ Do not reuse the differential cage bolts and
nuts.
4) Remove the side gear and side gear thrust washer
from differential cage A.
5) Remove the following parts from differential cage
B.
SST: 9-8521-0152-0 - bearing remover ・ Spider
・ Pinion gear
・ Pinion gear thrust washer
・ Side gear
・ Side gear thrust washer

4. Differential cage disassembly

1) Apply alignment marks to differential cage A and
differential cage B.
1. Side gear
3B-38 Differentials
2. Pinion gear

6) Remove the ring gear from differential cage B.

Caution：
・ Do not remove the ring gear tightening bolt for
any reason other than to replace the ring gear.
That is because LOCTITE is applied to the ring gear
tightening bolt.
 Differentials 3B-39

inspection ・ Excessive play, spalling, wear, and damage

・ Abnormal feeling when rotated by hand
1. Final drive inspection
1) Inspect each bearing for the following.
・ Excessive play, spalling, wear, and damage of the
inner race, outer race, and roller
・ Abnormal feeling when rotated by hand

3. Differential cage inspection

1. Visual inspection
1) Inspect the side gear tooth surface for the following.
・ Wear
・ Damage
2. Drive pinion inspection
・ Pitching
1) Inspect the drive pinion tooth surface for the
following.
・ Wear
・ Damage
・ Pitching
Caution：
・ Replace the drive pinion with the ring gear as
a set.

2) Inspect the side gear thrust washer for the

following.
・ Significant wear
・ Damage
3) Inspect the pinion gear for the following.
・ Tooth surface and inner surface wear
・ Tooth surface and inner surface damage
・ Tooth surface pitting
2) Inspect each bearing for the following.
3B-40 Differentials
Clearance between the differential cage and the side
gear
Standard value Limit
0.18 to 0.25 mm { 0.0071
0.5 mm { 0.0197 in }
to 0.0098 in }

4) Inspect the pinion gear thrust washer for the

following.
・ Significant wear
・ Damage
5) Inspect the ring gear for the following.
・ Wear 3. Measurement of play of the side gear spline in the
・ Damage rotational direction
・ Pitching 1) Insert the axle shaft into the side gear.
Caution： 2) Measure the play of the side gear spline in the
・ Replace the ring gear with the drive pinion as rotational direction.
a set.
Play of the spline in the rotational direction
Standard value Limit
0.2 mm or less { 0.0079 in
0.5 mm { 0.0197 in }
or less }

2. Measurement of clearance between the differential

cage and side gear
1) Measure the inner diameter of the differential cage.
2) Measure the outer diameter of the side gear. 4. Measurement of clearance between the spider and
the pinion gear
3) Calculate the clearance size from the measured
value. 1) Measure the outer diameter of the spider.
 Differentials 3B-41
2) Measure the inner diameter of the pinion gear.
3) Calculate the clearance size from the measured
value.
Clearance between the spider and the pinion gear
Standard value Limit
0.06 to 0.15 mm { 0.0024
0.3 mm { 0.0118 in }
to 0.0059 in }

5. Measurement of pinion gear thrust washer thickness

1) Measure the pinion gear thrust washer thickness.
Pinion gear thrust washer thickness
Standard value Limit
1.6 mm { 0.0630 in } 1.5 mm { 0.0591 in }
3B-42 Differentials

reassembly 1. Component views

Rear final drive (Single) (17.5H, 18.5H)

Part name 13. Lock washer (Except 18.5H)

14. Adjust nut
1. Drive pinion
15. Side bearing
2. Retainer
16. Differential cage
3. Pilot bearing
4. Retainer Tightening torque
5. Snap ring
6. Cotter pin 1: 402 N・m { 41.0 kgf・m / 296 lb・ft }
7. Shim 2: 20 N・m { 2.0 kgf・m / 15 lb・ft } 17.5H
8. Differential carrier
9. Adjust nut 2: 26 N・m { 2.7 kgf・m / 19 lb・ft } 18.5H
10. Side bearing 3: 13 N・m { 1.3 kgf・m / 115 lb・in }
11. Bearing cap
12. Lock plate 4: 185 N・m { 18.9 kgf・m / 136 lb・ft }
 Differentials 3B-43

Rear drive pinion (Single) (17.5H, 18.5H)

Part name 8. Pinion cage

9. Inner bearing
1. Flange nut
10. Drive pinion
2. O-ring
11. Pilot bearing
3. Flange
12. Snap ring
4. Oil seal
5. Outer bearing Tightening torque
6. Spacer
7. Shim 1: 834 N・m { 85.0 kgf・m / 615 lb・ft }
3B-44 Differentials

Rear differential cage (Single) (17.5H, 18.5H)

Part name 2) Install the ring gear to differential cage B.

1. Differential cage A Tightening torque: 431 N・m { 43.9 kgf・m / 318 lb・
2. Side gear thrust washer ft }
3. Side gear
4. Pinion gear thrust washer
5. Pinion gear
6. Side gear
7. Side gear thrust washer
8. Spider
9. Differential cage B and ring gear

Tightening torque
1: 206 N・m { 21.0 kgf・m / 152 lb・ft }
2: 431 N・m { 43.9 kgf・m / 318 lb・ft }
2. Final drive safety information
When assembling, if nothing in particular is specified,
refer to the following and apply or add differential oil.
Refer to "[Link] Information [Link]
Information Recommended fluids, lubricants and diesel
fuels". 1. Bolt
3. Differential cage reassembly
3) Apply differential oil to the following parts.
1) Apply LOCTITE 271 or equivalent to the threaded
portion of the bolt. ・ Side gear thrust washer
・ Side gear
 Differentials 3B-45
・ Spider
・ Pinion gear
・ Pinion gear thrust washer
4) Install the side gear thrust washer and side gear to
differential cage A.
5) Install the following parts to differential cage B.
・ Side gear thrust washer
・ Side gear
・ Spider
・ Pinion gear
・ Pinion gear thrust washer

1. Alignment mark

7) Measure the gap of the side gear.

Side gear clearance
Standard value
0.29 to 0.38 mm { 0.0114 to 0.0150 in }

1. Side gear
2. Pinion gear

6) Temporarily tighten differential cage A to

differential cage B.
Note：
・ Install according to the alignment marks
applied during disassembly.
Caution：
・ Do not reuse the nuts or bolts.
Tightening torque: 98 N・m { 10.0 kgf・m / 72 lb・ft }
Caution：
・ If the side gear clearance is not within the
specified range, replace the side gear thrust
washer and adjust.
Thickness of the applicable side gear thrust washer
2.8 mm { 0.1102 in }
2.9 mm { 0.1142 in }
3.0 mm { 0.1181 in }
3.1 mm { 0.1220 in }
3.2 mm { 0.1260 in }
3.3 mm { 0.1299 in }
3.4 mm { 0.1339 in }
3B-46 Differentials
8) Final tighten differential cage A to differential cage
B.
Tightening torque: 206 N・m { 21.0 kgf・m / 152 lb・
ft }
9) Stake the nuts in 2 places.

1. Snap ring

4) Install the inner bearing outer race to the pinion

cage.
5) Install the outer bearing outer race to the pinion
cage.
4. Drive pinion reassembly 6) Temporarily tighten the following parts using the
1) Install the inner bearing inner race to the drive special tool.
pinion using a press. ・ Pinion cage
・ Shim
・ Spacer
・ Outer bearing
・ Flange

SST: 9-8522-1243-1 - spline yoke bracket

Tightening torque: 834 N・m { 85.0 kgf・m / 615 lb・
ft }

2) Install the inner race of the pilot bearing to the drive

pinion using a copper hammer or brass rod, etc.
3) Install the snap ring to the drive pinion.
 Differentials 3B-47

8.6 mm { 0.3386 in }
8.8 mm { 0.3465 in }
9.0 mm { 0.3543 in }
Applicable shim
3.25 mm { 0.1280 in }
3.26 mm { 0.1283 in }
3.27 mm { 0.1287 in }
3.28 mm { 0.1291 in }
3.29 mm { 0.1295 in }
3.30 mm { 0.1299 in }
3.31 mm { 0.1303 in }
3.32 mm { 0.1307 in }
3.33 mm { 0.1311 in }
3.34 mm { 0.1315 in }
3.35 mm { 0.1319 in }
7) Hook the spring scale onto the bolt hole of the 9) Remove the flange nut and flange from the pinion
pinion cage. cage.
8) Pull the spring scale in the tangential direction and 10) Apply LOCTITE 242 or equivalent to the outer
measure the preload of the pinion cage. circumference of the oil seal.
Standard value 11) Apply chassis type grease to the lip section of the
37.3 to 48.1 N・m { 3.8 to 4.9 kgf・m / 28 to 35 lb・ oil seal.
ft }

1. Outer circumference of the oil seal

Caution： 2. Lip section of the oil seal
・ When the measured preload is outside the
12) Apply chassis type grease to the O-ring.
specified range, make adjustments using the
spacer and shim. 13) Install the oil seal to the flange.
Applicable spacer 14) Install the flange nut and flange to the pinion cage.
7.6 mm { 0.2992 in } Tightening torque: 834 N・m { 85.0 kgf・m / 615 lb・
7.8 mm { 0.3071 in } ft }
8.0 mm { 0.3150 in }
8.2 mm { 0.3228 in }
8.4 mm { 0.3307 in }
3B-48 Differentials

15) Stake the flange nut in 2 places. 5) Install the differential cage to the differential
carrier.
Note：
・ Stake so that firm contact is made with the 6) Install the bearing cap, side bearing outer race, and
groove surface on the tightening direction side. adjust nut to the differential carrier.

5. Final drive reassembly Note：

・ Install according to the alignment marks
1) Install the pilot bearing outer race to the differential
applied during disassembly.
carrier, with the snap ring side set to the bearing cap
side.

1. Alignment mark
1. Snap ring 7) Tighten the adjust nut according to the alignment
marks applied during disassembly.
2) Install the retainer to the differential carrier.
Tightening torque: 13 N・m { 1.3 kgf・m / 10 lb・ft }
3) Apply a detent to the cotter pin.
4) Install the side bearing inner race to the differential
cage using a brass rod, etc.
 Differentials 3B-49
Caution：
・ When the measured preload is outside the
specified range, make adjustments with the
adjust nut.
11) Measure the runout of the ring gear using the dial
gauge.
Ring gear runout
Standard value Limit
0.1 mm or less { 0.0039 in
0.2 mm { 0.0079 in }
or less }
Caution：
・ When the measured runout is more than the
limit, repair or replace the ring gear or the side
bearing.

1. Alignment mark

8) Temporarily tighten the bearing cap bolt to the

differential carrier.
Tightening torque: 49 N・m { 5.0 kgf・m / 36 lb・ft }
9) Hook the spring scale onto the tightening bolt of the
ring gear.
10) Pull the spring scale in the tangential direction, and
measure the preload of the side bearing.
Side bearing preload
Standard value
24.5 to 49.0 N・m { 2.5 to 5.0 kgf・m / 18 to 36 lb・
ft }
Side bearing preload
Standard value 12) Temporarily tighten the drive pinion and shim to
44.1 to 88.3 N・m { 4.5 to 9.0 kgf・m / 33 to 65 lb・ the differential carrier.
ft } Note：
・ Install by aligning with the oil hole of the
differential carrier.
Caution：
・ Do not apply liquid gasket at this point.
Tightening torque: 185 N・m { 18.9 kgf・m / 136 lb・
ft }
3B-50 Differentials
Note：
・ At this time, to prevent a change in preload of
the side bearing, tighten an adjust nut to the
same degree as the other adjust nut was
loosened.
16) Clean the gear teeth of the ring gear and of the drive
pinion.
17) Apply red lead primer to the gear teeth of the ring
gear.
Note：
・ Apply to both surfaces of 7 to 8 gear teeth.
18) Gently move the ring gear back and forth while
holding the drive pinion by hand, and inspect the
tooth contact of the ring gear and drive pinion.

1. Oil hole
2. Shim

13) Secure the dial gauge stand to the flange surface of

the differential carrier.
14) Apply the gauge head of the dial gauge to the rear
surface of the ring gear, and set the long needle of
the dial gauge to 0.
15) Gently move the ring gear back and forth while
pressing the drive pinion by hand, then measure the
backlash of the ring gear and drive pinion.
Ring gear and drive pinion
Standard value
0.28 to 0.36 mm { 0.0110 to 0.0142 in }

19) Correct contact is 70% of the full length of the gear

centered on the pitch line, towards the heel side
(Outer side), and leaving approximately 5 mm {0.2
in} to the toe side (Inner side).

Caution：
・ When the measured backlash is outside the
specified range, adjust the position of the
differential cage with the adjust nut.
 Differentials 3B-51
Caution： tooth contact of the ring gear and drive pinion
・ Refer to the following diagram to adjust the is found to be incorrect as a result of the
positions of the ring gear and drive pinion if the inspection.

20) Apply ThreeBond TB1110D or equivalent to the

pinion cage, differential carrier, and between the
shims.
3B-52 Differentials

1. Between the shims

21) Install the pinion cage to the differential carrier.

Tightening torque: 185 N・m { 18.9 kgf・m / 136 lb・
ft }
22) Securely tighten the bearing cap bolt to the
differential carrier.
Tightening torque: 402 N・m { 41.0 kgf・m / 296 lb・
ft }

23) Apply LOCTITE 242 or equivalent to the threaded

portion of the bolt.
24) Align the lock plate with the adjust nut groove to
install.
Tightening torque: 26 N・m { 2.7 kgf・m / 19 lb・ft }
 Differentials 3B-53

installation 1. Component views

Rear differential (Single)

Part name
1. Filler plug
2. Drain plug
3. Final drive

Tightening torque
1: 69 N・m { 7.0 kgf・m / 51 lb・ft }
2: 69 N・m { 7.0 kgf・m / 51 lb・ft }
3: 219 N・m { 22.3 kgf・m / 162 lb・ft }
2. Final drive installation
1) Clean the bolts and the rear axle case.
Note：
・ Clean any LOCTITE remaining on the re-used
bolts and the screw holes.
・ Clean the bolts with the die and the screw hole
1. Bolt hole
with the tap as necessary.
2. Rear axle case differential carrier installation
2) Apply LOCTITE 242 or equivalent to the threaded surface
portion of the bolt.
4) Install the final drive to the rear axle case.
3) Apply LOCTITE FMD127 or equivalent to the rear
axle case differential carrier installation surface. Tightening torque: 219 N・m { 22.3 kgf・m / 162 lb・
ft }
3. Rear axle shaft installation
1) Install the rear axle shaft to the rear axle.
Tightening torque: 182 N・m { 18.6 kgf・m / 134 lb・
ft }
3B-54 Differentials

・ If the center bearing assembly mounting bolts

and nuts of P90HS are M16 x 1.5, install the
cotter pins to the nuts.
・ When installing the cotter pin, if the nut groove
and hole do not align, tighten further and align
at an angle of 30° or less.
206 N・m { 21.0
Transmission flange
kgf・m / 152 lb・ft }
186 N・m { 19.0
Center bearing
kgf・m / 137 lb・ft }
206 N・m { 21.0
Center bearing flange
kgf・m / 152 lb・ft }
206 N・m { 21.0
Axle flange
kgf・m / 152 lb・ft }

Transmission flange

4. Propeller shaft installation

Caution：
・ Install according to the alignment marks
placed during removal.
1) Clean the flange yoke and flange installation
surfaces so that no grease, oil, paint, or other
foreign material is present.

Center bearing (Propeller shaft with center bearing)

2) Install the propeller shaft to vehicle.

Note：
・ Install in order starting from the front of the
vehicle and moving rearward.
・ When installing the center bearing assembly,
temporarily tighten to the vehicle, and then
final tighten after adjusting the center bearing
assembly mounting section so that it is level
with the frame using the oblong holes.
 Differentials 3B-55

Center bearing flange (Propeller shaft with center 2. Differential oil refill procedure (Rear differential
bearing) [single])
1) Install the drain plug to the rear axle case.
Tightening torque: 69 N・m { 7.0 kgf・m / 51 lb・ft }
2) Add differential oil to the rear axle case.

Axle flange

1. Filler plug hole

3) Install the filler plug to the rear axle case.

Tightening torque: 69 N・m { 7.0 kgf・m / 51 lb・ft }
4) Lower the vehicle.
6. Preliminary and post procedures
1. Post procedures
1) Lower the vehicle.

3) Lubricate the propeller shaft.

4) Install the propeller shaft guard to the vehicle if one
exists.
Tightening torque: 48 N・m { 4.9 kgf・m / 35 lb・ft }
5. Differential oil filling
1. Differential oil amount and brand
For the differential oil refill amount, refer to the
following.
Refer to "[Link], Axle [Link]
Information Primary specifications of driveline, axle".
For the differential oil brand, refer to the following.
Refer to "[Link] Information [Link]
Information Recommended fluids, lubricants and diesel
fuels".
3B-56 Differentials

Rear differential (tandem)（17.5HT）

removal 1. Component views

Rear differential (Tandem)

Part name
1. Filler plug
2. Drain plug
3. Final drive
4. Strainer plug

Tightening torque
1: 69 N・m { 7.0 kgf・m / 51 lb・ft }
2: 69 N・m { 7.0 kgf・m / 51 lb・ft }
3: 219 N・m { 22.3 kgf・m / 162 lb・ft }
4: 69 N・m { 7.0 kgf・m / 51 lb・ft }
2. Preliminary and post procedures
1. Preliminary procedures
1) Raise the vehicle.
3. Differential oil drain 1. Strainer plug
2. Drain plug
1) Remove the drain plug from the rear axle case, and
drain the differential oil. 4. Propeller shaft removal
2) Remove the strainer plug from the power divider Caution：
case, and drain the differential oil.
・ Because the propeller shaft is adjusted to have
Caution： a precise balance, always place an alignment
・ Do not reuse the O-ring. mark on each of the joints before removing,
disassembling, etc.
 Differentials 3B-57

Center bearing flange (Propeller shaft with center

bearing)

1) Remove the propeller shaft guard from the vehicle

if one exists.
2) Remove the propeller shaft from vehicle. Transmission flange
Note：
・ Remove in order starting from the rear of the
vehicle and moving forward.

Axle flange

5. Propeller shaft between tandem axles removal

Caution：
・ Because the propeller shaft is adjusted to have
a precise balance, always place an alignment
mark for each of the joints before removing,
disassembling, etc.
1) Remove the propeller shaft between the axles from
the vehicle.
Caution：
・ Remove the needle bearing while taking care
not to drop it.
3B-58 Differentials
4) Remove the snap ring from the axle case using snap
ring pliers.
5) Remove the output shaft from the axle case.
Note：
・ Remove the following parts at the same time.
・ Shim
・ Outer bearing outer race
・ Outer bearing inner race
・ Inner bearing inner race

6. Nylon tube air hose disconnect

1) Disconnect the nylon tube air hose from the inter-
axle differential lock shift unit.
7. Rear axle shaft removal
1) Remove the rear axle shaft from the rear axle.
8. Output shaft removal
1) Pry up the stake of the flange nut using a punch.

6) Remove the following parts from the output shaft.

・ Shim
・ Outer bearing outer race
・ Outer bearing inner race
・ Inner bearing inner race
9. Final drive removal
1) Remove the bolts from the differential carrier.
2) Install the bolts to the replace bolt holes of the
differential carrier, and pull out the final drive from
the rear axle case.

2) Remove the flange from the output shaft.

Note：
・ Remove the following parts at the same time.
・ Dust cover
・ Oil seal
3) Remove the following parts from the flange.
・ Oil seal
・ Dust cover
 Differentials 3B-59

1. Replace bolt holes

2. Replace bolt holes

3) Remove the inner bearing outer race from the rear

axle case.
3B-60 Differentials

disassembly 1. Component views

Rear final drive (Tandem) (17.5HT)

Part name 16. Snap ring

17. Thrust washer
1. Oil pickup
18. Nut
2. Differential carrier
19. O-ring
3. Adjust nut
20. Flange
4. Side bearing
21. Oil seal
5. Differential
22. Bearing retainer
6. Bearing cap
23. Shim
7. Lock plate
24. Input shaft bearing
8. Lock washer
25. Power divider case
9. Adjust nut
26. Seal ring
10. Side bearing
27. Differential lock switch
11. Input shaft bearing
28. Input shaft
12. Oil catcher
29. Plug
13. Side gear
30. Thrust washer
14. Spacer
31. Input shaft bearing
15. Needle bearing
 Differentials 3B-61
32. Driven helical gear 1: 26 N・m { 2.7 kgf・m / 19 lb・ft }
33. Snap ring
2: 402 N・m { 41.0 kgf・m / 296 lb・ft }
34. Spider
35. Differential cage 3: 20 N・m { 2.0 kgf・m / 15 lb・ft }
36. Pinion gear thrust washer
4: 51 N・m { 5.2 kgf・m / 38 lb・ft }
37. Pinion gear
38. Inter-axle differential lock shift unit 5: 50 N・m { 5.1 kgf・m / 37 lb・ft }
39. Spring 6: 13 N・m { 1.3 kgf・m / 115 lb・in }
40. Strainer
41. Oil pump assembly 7: 185 N・m { 18.9 kgf・m / 136 lb・ft }
42. Drive pinion assembly 8: 69 N・m { 7.0 kgf・m / 51 lb・ft }
43. Shim
44. Retainer 9: 18 N・m { 1.8 kgf・m / 13 lb・ft }
45. Snap ring 10: 686 N・m { 70.0 kgf・m / 506 lb・ft }
46. Cotter pin
47. Pilot bearing 11: 98 N・m { 10.0 kgf・m / 72 lb・ft }
12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Tightening torque

Rear drive pinion (Tandem) (17.5HT)

Part name 7. Inner bearing

8. Drive pinion
1. Pinion nut
9. Pilot bearing
2. Driven helical gear
10. Snap ring
3. Outer bearing
4. Pinion cage Tightening torque
5. Shim
6. Spacer 1: 834 N・m { 85.0 kgf・m / 615 lb・ft }
3B-62 Differentials

Rear differential cage (Tandem) (17.5HT)

Part name
1. Differential cage A
2. Side gear thrust washer
3. Side gear
4. Pinion gear thrust washer
5. Pinion gear
6. Side gear
7. Side gear thrust washer
8. Spider
9. Differential cage B and ring gear

Tightening torque
1: 206 N・m { 21.0 kgf・m / 152 lb・ft }
2: 431 N・m { 43.9 kgf・m / 318 lb・ft }
2. Inter axle differential lock shift unit removal
1) Remove the differential lock shift unit from the
power divider case. 2) Remove the flange nut from the input shaft.
3. Final drive disassembly 3) Remove the flange and O-ring from the power
divider case.
1) Pry up the stake section of the flange nut using a
punch.
 Differentials 3B-63

1. O-ring 7) Remove the outer race of the input shaft bearing

from the power divider case.
4) Remove the bearing retainer and shim from the
power divider case.

8) Remove the differential lock clutch from the power

divider case.
5) Remove the oil seal from the power divider case.
9) Remove the input shaft from the differential carrier.
6) Remove the power divider case from the differential
carrier.
3B-64 Differentials

10) Remove the seal ring and snap ring from the input 12) Remove the thrust washer from the input shaft.
shaft.

13) Remove the drive helical gear from the differential

11) Remove the needle bearing from the input shaft. carrier.
 Differentials 3B-65

14) Remove the differential cage from the differential 17) Remove the following parts from differential cage
carrier. B.
・ Pinion gear
・ Pinion gear thrust washer
・ Spider

15) Apply alignment marks to the differential cage.

16) Remove differential cage A from differential cage
B.
18) Remove the thrust washer from the side gear.
19) Remove the oil catcher from the differential carrier.
20) Remove the side gear from the differential carrier.
3B-66 Differentials

21) Remove the following parts from the side gear. 24) Remove the pinion nut from the drive pinion by
detenting the ring gear.
・ Snap ring
・ Input shaft bearing
・ Spacer
22) Remove the oil pickup from the differential carrier.

25) Remove the driven helical gear from the drive

pinion.
26) Remove the bolt from the pinion cage.
23) Pry up the stake of the pinion nut using a punch. 27) Temporarily install the driven helical gear and the
pinion nut, and then remove the drive pinion and
the shim from the differential carrier.
Caution：
・ Store the shim in a safe location to prevent
damage.
 Differentials 3B-67

1. Shim 1. Lock washer

2. Lock plate
28) Apply right and left identification marks to the
adjust nut and bearing cap. 30) Apply alignment marks to the bearing cap and the
differential carrier.

1. Alignment mark
1. Alignment mark
29) Remove the lock washer and lock plate from the
bearing cap. 31) Remove the bearing cap from the differential
carrier.
32) Remove the adjust nut from the differential carrier.
33) Remove the side bearing outer race from the
differential carrier.
Note：
・ Put tags on the removed bearing caps, adjust
nuts, side bearing outer races, etc., to identify
that they are for the right or left side.
3B-68 Differentials

34) Remove the differential cage from the differential 37) Pull out the cotter pin from the retainer bolt.
carrier.
38) Remove the following parts from the differential
Note： carrier.
・ At this time, remove the differential cage by ・ Retainer
pulling it to the ring gear side to prevent it from ・ Nut
getting caught on the pilot bearing section. ・ Bolt
・ Pilot bearing outer race

35) Apply right and left identification marks to the side

bearing. 1. Pilot bearing outer race
36) Remove the side bearing inner race from the 39) Remove the oil pump and 2 bolts from the power
differential cage using the special tool. divider case.
Caution：
・ Take care not to lose the gasket and drive
gear.
Note：
・ If there is no failure, remove the 4 cover bolts
and rotate the shaft by hand. Do not
SST: 9-8521-0131-0 - bearing remover disassemble if they rotate smoothly.
 Differentials 3B-69

40) Remove the following parts from the power divider 2) Push the snap ring into the snap ring groove by
case. inserting the special tool between the drive pinion
and the pilot bearing inner race.
・ Strainer
・ Strainer plug
・ Spring
・ O-ring

SST: 1-8521-9009-0 - pilot bearing remover

1. Strainer

Note：
・ If the strainer is dirty, remove contamination
with diesel oil or equivalent.
4. Drive pinion disassembly 1. Snap ring
1) Remove the following parts from the drive pinion 2. 1-8521-9009-0
by tapping the rear of the drive pinion lightly with a
3) Remove the pilot bearing inner race from the drive
copper hammer.
pinion using the special tool.
・ Pinion bearing
・ Shim
・ Spacer
・ Pinion cage
3B-70 Differentials
5. Differential cage disassembly
1) Apply alignment marks to differential cage A and
differential cage B.

SST: 9-8521-0182-0 - bearing remover

1. Alignment mark

2) Remove differential cage A from differential cage

B.
3) Remove the side gear and side gear thrust washer
4) Remove the inner bearing from the drive pinion from differential cage A.
using the special tool.
4) Remove the following parts from differential cage
B.
・ Spider
・ Pinion gear
・ Pinion gear thrust washer
・ Side gear
・ Side gear thrust washer

SST: 9-8521-0152-0 - bearing remover

1. Side gear
2. Pinion gear
 Differentials 3B-71
5) Remove the ring gear from differential cage B as
necessary.
Caution：
・ Do not remove the ring gear tightening bolt for
any reason other than to replace the ring gear.
That is because LOCTITE is applied to the ring gear
tightening bolt.
3B-72 Differentials

inspection
1. Final drive inspection
1. Visual inspection
1) Inspect each bearing for the following.
・ Excessive play, spalling, wear, and damage of the
inner race, outer race, and roller
・ Abnormal feeling when rotated by hand

4) Inspect the pinion gear for the following.

・ Wear
・ Damage
・ Pitching

2) Inspect the driven helical gear for the following.

・ Wear
・ Damage
・ Pitching

2. Measurement of clearance between the shift fork

and clutch
1) Measure the clearance between the shift fork and
the clutch.
Clearance
Standard value Limit
0.2 to 0.4 mm { 0.0079 to
0.2 mm { 0.0079 in }
0.0157 in }
3) Inspect the side gear for the following.
・ Wear
・ Damage
・ Pitching
 Differentials 3B-73
Clearance
Standard value Limit
0.06 to 0.15 mm { 0.0024
0.3 mm { 0.0118 in }
to 0.0059 in }

1. Clearance between the shift fork and the clutch

3. Measurement of side gear spline play in the

rotational direction
1) Insert the output shaft into the side gear.
5. Measurement of pinion gear thrust washer thickness
2) Measure the play of the side gear spline in the
1) Measure the pinion gear thrust washer thickness.
rotational direction using a dial gauge.
Pinion gear thrust washer thickness
Play in the spline rotation direction
Standard value Limit
Standard value Limit
1.6 mm { 0.0630 in } 1.5 mm { 0.0591 in }
0.2 mm or less { 0.0079 in
0.5 mm { 0.0197 in }
or less }

2. Drive pinion inspection

4. Measurement of clearance between the spider and 1) Inspect the drive pinion gear for the following.
the pinion gear
・ Wear
1) Measure the external diameter of the spider. ・ Damage
・ Pitching
2) Measure the inner diameter of the pinion gear.
3) Calculate the clearance between the spider and the
pinion gear from the measured values.
3B-74 Differentials

Caution： 3. Differential cage inspection

・ Replace the drive pinion with the ring gear as 1. Visual inspection
a set.
1) Inspect the side gear tooth surface for the following.
2) Inspect the driven helical gear for the following.
・ Wear
・ Wear ・ Damage
・ Damage ・ Pitching
・ Pitching
・ Play between the drive pinion and spline fitting

2) Inspect the side gear thrust washer for the

following.
3) Inspect each bearing for the following.
・ Significant wear
・ Excessive play, spalling, wear, and damage ・ Damage
・ Abnormal feeling when rotated by hand
3) Inspect the pinion gear tooth surface for the
following.
・ Tooth surface and inner surface wear
・ Tooth surface and inner surface damage
・ Tooth surface pitting
 Differentials 3B-75
Clearance
Standard value Limit
0.13 to 0.21 mm { 0.0051
0.5 mm { 0.0197 in }
to 0.0083 in }

4) Inspect the pinion gear thrust washer for the

following.
・ Significant wear
・ Damage
5) Inspect the ring gear for the following. 3. Measurement of play of the side gear spline in the
・ Wear rotational direction
・ Damage 1) Insert the axle shaft into the side gear.
・ Pitching
2) Measure the play of the side gear spline in the
rotational direction.
Play in the rotational direction
Standard value Limit
0.2 mm or less { 0.0079 in
0.5 mm { 0.0197 in }
or less }

Caution：
・ Replace the ring gear with the drive pinion as
a set.
2. Measurement of clearance of the differential cage
and side gear
1) Measure the inner diameter of the differential cage.
4. Measurement of clearance between the spider and
2) Measure the outer diameter of the side gear. the pinion gear
3) Calculate the clearance from the measured values. 1) Measure the outer diameter of the spider.
2) Measure the inner diameter of the pinion gear.
3B-76 Differentials
3) Calculate the clearance from the measured values.
Clearance
Standard value Limit
0.06 to 0.15 mm { 0.0024
0.3 mm { 0.0118 in }
to 0.0059 in }

5. Measurement of pinion gear thrust washer thickness

1) Measure the pinion gear thrust washer thickness.
Pinion gear thrust washer thickness
Standard value Limit
1.6 mm { 0.0630 in } 1.5 mm { 0.0591 in }
 Differentials 3B-77

reassembly 1. Component views

Rear final drive (Tandem) (17.5HT)

Part name 16. Snap ring

17. Thrust washer
1. Oil pickup
18. Nut
2. Differential carrier
19. O-ring
3. Adjust nut
20. Flange
4. Side bearing
21. Oil seal
5. Differential
22. Bearing retainer
6. Bearing cap
23. Shim
7. Lock plate
24. Input shaft bearing
8. Lock washer
25. Power divider case
9. Adjust nut
26. Seal ring
10. Side bearing
27. Differential lock switch
11. Input shaft bearing
28. Input shaft
12. Oil catcher
29. Plug
13. Side gear
30. Thrust washer
14. Spacer
31. Input shaft bearing
15. Needle bearing
3B-78 Differentials
32. Driven helical gear 1: 26 N・m { 2.7 kgf・m / 19 lb・ft }
33. Snap ring
2: 402 N・m { 41.0 kgf・m / 296 lb・ft }
34. Spider
35. Differential cage 3: 20 N・m { 2.0 kgf・m / 15 lb・ft }
36. Pinion gear thrust washer
4: 51 N・m { 5.2 kgf・m / 38 lb・ft }
37. Pinion gear
38. Inter-axle differential lock shift unit 5: 50 N・m { 5.1 kgf・m / 37 lb・ft }
39. Spring 6: 13 N・m { 1.3 kgf・m / 115 lb・in }
40. Strainer
41. Oil pump assembly 7: 185 N・m { 18.9 kgf・m / 136 lb・ft }
42. Drive pinion assembly 8: 69 N・m { 7.0 kgf・m / 51 lb・ft }
43. Shim
44. Retainer 9: 18 N・m { 1.8 kgf・m / 13 lb・ft }
45. Snap ring 10: 686 N・m { 70.0 kgf・m / 506 lb・ft }
46. Cotter pin
47. Pilot bearing 11: 98 N・m { 10.0 kgf・m / 72 lb・ft }
12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
Tightening torque

Rear drive pinion (Tandem) (17.5HT)

Part name 7. Inner bearing

8. Drive pinion
1. Pinion nut
9. Pilot bearing
2. Driven helical gear
10. Snap ring
3. Outer bearing
4. Pinion cage Tightening torque
5. Shim
6. Spacer 1: 834 N・m { 85.0 kgf・m / 615 lb・ft }
 Differentials 3B-79

Rear differential cage (Tandem) (17.5HT)

Part name 2) Install the ring gear to differential cage B.

1. Differential cage A Tightening torque: 431 N・m { 43.9 kgf・m / 318 lb・
2. Side gear thrust washer ft }
3. Side gear
4. Pinion gear thrust washer
5. Pinion gear
6. Side gear
7. Side gear thrust washer
8. Spider
9. Differential cage B and ring gear

Tightening torque
1: 206 N・m { 21.0 kgf・m / 152 lb・ft }
2: 431 N・m { 43.9 kgf・m / 318 lb・ft }
2. Final drive safety information
When assembling, if nothing in particular is specified,
refer to the following and apply or add differential oil.
Refer to "[Link] Information [Link]
Information Recommended fluids, lubricants and diesel
fuels". 1. Bolt
3. Differential cage reassembly
3) Apply differential oil to the following parts.
1) Apply LOCTITE 271 or equivalent to the threaded
portion of the bolt. ・ Side gear thrust washer
・ Side gear
3B-80 Differentials
・ Spider
・ Pinion gear
・ Pinion gear thrust washer
4) Install the side gear thrust washer and side gear to
differential cage A.
5) Install the following parts to differential cage B.
・ Side gear thrust washer
・ Side gear
・ Spider
・ Pinion gear
・ Pinion gear thrust washer

1. Alignment mark

7) Measure the side gear clearance.

Clearance
Standard value
0.23 to 0.32 mm { 0.0091 to 0.0126 in }

1. Side gear
2. Pinion gear

6) Temporarily tighten differential cage A to

differential cage B.
Note：
・ Install according to the alignment marks
applied during disassembly.
Caution：
・ Do not reuse the nuts or bolts.
Tightening torque: 98 N・m { 10.0 kgf・m / 72 lb・ft }
Caution：
・ If the side gear clearance is not within the
standard range, change the side gear thrust
washer and adjust.
Thickness of the applicable side gear thrust washer
2.8 mm { 0.1102 in }
2.9 mm { 0.1142 in }
3.0 mm { 0.1181 in }
3.1 mm { 0.1220 in }
3.2 mm { 0.1260 in }
3.3 mm { 0.1299 in }
3.4 mm { 0.1339 in }
 Differentials 3B-81
8) Final tighten differential cage A to differential cage
B.
Tightening torque: 206 N・m { 21.0 kgf・m / 152 lb・
ft }

1. Pilot bearing inner race

4) Install the inner bearing outer race to the pinion

gauge.
5) Install the outer bearing outer race to the pinion
4. Drive pinion reassembly gauge.
1) Install the inner bearing inner race to the drive 6) Install the pinion cage to the drive pinion.
pinion using a press.
7) Install the shim to the drive pinion.
8) Install the spacer to the drive pinion.
9) Install the outer bearing inner race to the drive
pinion.
10) Install the driven helical gear to the drive pinion.
Tightening torque: 834 N・m { 85.0 kgf・m / 615 lb・
ft }

2) Install the snap ring to the snap ring groove of the

drive pinion.
3) Install the inner race of the pilot bearing to the drive
pinion using a copper hammer or brass rod.
Note：
・ Set the more heavily chamfered side of the
inner race to the drive pinion side.
11) Hook the spring scale onto the bolt hole of the
pinion cage.
3B-82 Differentials
12) Pull the spring scale in the tangential direction and Tightening torque: 834 N・m { 85.0 kgf・m / 615 lb・
measure the preload of the pinion cage. ft }
Preload of the pinion cage 5. Final drive reassembly
Standard value 1) Install the pilot bearing to the differential carrier,
35.3 to 45.1 N { 3.6 to 4.6 kg / 7.9 to 10.1 lb } with the snap ring side set to the bearing cap side.

Caution： 1. Snap ring

・ When the measured preload is outside the
standard range, make adjustments using the 2) Install the retainer to the differential carrier and
spacer and shim. detent with the cotter pin.

Applicable spacer Tightening torque: 13 N・m { 1.3 kgf・m / 115 lb・in }

7.6 mm { 0.2992 in } 3) Install the side bearing to the differential cage using
7.8 mm { 0.3071 in } a press or brass rod.
8.0 mm { 0.3150 in }
8.2 mm { 0.3228 in }
8.4 mm { 0.3307 in }
8.6 mm { 0.3386 in }
8.8 mm { 0.3465 in }
9.0 mm { 0.3543 in }
Applicable shim
3.25 mm { 0.1280 in }
3.26 mm { 0.1283 in }
3.27 mm { 0.1287 in }
3.28 mm { 0.1291 in }
3.29 mm { 0.1295 in }
3.30 mm { 0.1299 in }
3.31 mm { 0.1303 in }
3.32 mm { 0.1307 in }
3.33 mm { 0.1311 in } 4) Install the differential cage to the differential
3.34 mm { 0.1315 in } carrier.
3.35 mm { 0.1319 in }
5) Install the bearing cap, side bearing outer race, and
13) Final tighten the pinion nut to the drive pinion. adjust nut to the differential carrier.
 Differentials 3B-83
Note： 24.5 to 49.0 N { 2.5 to 5.0 kg / 5.5 to 11.0 lb }
・ Install according to the alignment marks Side bearing preload
applied during disassembly.
Standard value
402 to 804 N⋅cm {40 to 80 kgf⋅cm / 36 to 71 lb⋅in}

1. Alignment mark

6) Tighten the adjust nut according to the alignment Caution：

marks applied during disassembly. ・ When the measured preload is outside the
specified range, make adjustments with the
adjust nut.
10) Measure the runout of the ring gear using the dial
gauge.
Ring gear runout
Standard value Limit
0.1 mm or less { 0.0039 in
0.2 mm { 0.0079 in }
or less }
Caution：
・ When the measured runout is more than the
limit, repair or replace the ring gear or the side
bearing.

1. Alignment mark

7) Temporarily tighten the bearing cap bolt to the

differential carrier.
Tightening torque: 49 N・m { 5.0 kgf・m / 36 lb・ft }
8) Hook the spring scale onto the tightening bolt of the
ring gear.
9) Pull the spring scale in the tangential direction, and
measure the preload of the side bearing.
Side bearing preload
Standard value
3B-84 Differentials

11) Temporarily tighten the drive pinion and shim to Caution：

the differential carrier. ・ When the measured backlash is outside the
Tightening torque: 185 N・m { 18.9 kgf・m / 136 lb・ specified range, adjust the position of the
ft } differential cage with the adjust nut.
Note：
・ At this time, to prevent a change in preload of
the side bearing, tighten an adjust nut to the
same degree as the other adjust nut was
loosened.
15) Clean the gear teeth of the ring gear and of the drive
pinion.
16) Apply red lead primer to the gear teeth of the ring
gear.
Note：
・ Apply to both surfaces of 7 to 8 gear teeth.
17) Gently move the ring gear back and forth while
holding the drive pinion by hand, and inspect the
tooth contact of the ring gear and drive pinion.

1. Shim

12) Secure the dial gauge stand to the flange surface of

the differential carrier.
13) Apply the gauge head of the dial gauge to the rear
surface of the ring gear, and set the long needle of
the dial gauge to 0.
14) Gently move the ring gear back and forth while
pressing the drive pinion by hand, then measure the
backlash of the ring gear and drive pinion.
Backlash
Standard value
0.28 to 0.36 mm { 0.0110 to 0.0142 in }
 Differentials 3B-85
Note： Caution：
・ Correct contact is 70% of the full length of the ・ Refer to the following diagram to adjust the
gear centered on the pitch line, towards the positions of the ring gear and drive pinion if the
heel side (outer side), and leaving tooth contact of the ring gear and drive pinion
approximately 5.0 mm {0.20 in} to the toe side is found to be incorrect as a result of the
(inner side). inspection.
3B-86 Differentials

18) Securely tighten the bearing cap bolt to the

differential carrier.
Tightening torque: 402 N・m { 41.0 kgf・m / 296 lb・
ft }
 Differentials 3B-87
19) Align the lock plate and lock washer with the adjust
nut groove to install.
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

24) Stake the pinion nut in 2 places.

Caution：
・ Stake so that firm contact is made with the
1. Lock washer groove surface on the tightening direction side.
2. Lock plate 25) Apply LOCTITE 242 or equivalent to the threaded
portion of the bolt.
20) Detent the bolt by bending the lock washer.
26) Temporarily tighten the oil pickup to the differential
21) Apply LOCTITE 242 or equivalent to the threaded
carrier.
portion of the bolt.
27) Final tighten the oil pickup with the outer diameter
22) Securely tighten the pinion cage to the differential
of the ring gear and the lip of the oil pickup in
carrier.
contact.
Tightening torque: 185 N・m { 18.9 kgf・m / 136 lb・
Tightening torque: 26 N・m { 2.7 kgf・m / 19 lb・ft }
ft }

1. Bolt
1. Bolt
2. Oil pickup
23) Install the driven helical gear to the drive pinion. 3. Ring gear

Tightening torque: 834 N・m { 85.0 kgf・m / 615 lb・ 28) Install the oil catcher to the differential carrier.
ft }
3B-88 Differentials
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } 34) Apply LOCTITE 242 or equivalent to the threaded
portion of the bolt.
29) Install the following parts to the side gear.
35) Install differential cage B to differential cage A.
・ Spacer
・ Needle bearing Caution：
・ Snap ring ・ Check that the 4 pinion gears rotate smoothly
・ Bearing inner race after tightening.
30) Install the side gear to the differential carrier.
Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }

31) Install the thrust washer to the differential carrier.

36) Install the differential cage to the differential carrier
32) Apply differential oil to the following parts. by positioning the bolt head to the side gear side.
・ Spider
・ Pinion gear
・ Pinion gear thrust washer
33) Install the following parts to the differential cage.
・ Spider
・ Pinion gear
・ Pinion gear thrust washer

37) Install the drive helical gear to the differential cage.

 Differentials 3B-89

38) Apply differential oil to the thrust washer and 41) Install the input shaft to the inside of the drive
needle bearing. helical gear.
39) Install the thrust washer and needle bearing to the 42) Measure the side gear end play by inserting the
input shaft. feeler gauge in between the input shaft and the drive
helical gear.
Note：
・ Install the thrust washer with the oil groove Side gear end play
facing the needle bearing side. Standard value
0.40 to 1.10 mm { 0.0157 to 0.0433 in }

40) Install the snap ring to the input shaft.

Caution：
・ When the measured side gear end play is
outside the specified range, make adjustments
by changing the thickness of the thrust
washer.
Thickness of the applicable thrust washer
5.9 mm { 0.2323 in }
6.0 mm { 0.2362 in }
6.1 mm { 0.2402 in }
6.2 mm { 0.2441 in }
3B-90 Differentials

6.3 mm { 0.2480 in } 47) Install the power divider case to the differential
6.4 mm { 0.2520 in } carrier.
6.5 mm { 0.2559 in } Tightening torque: 126 N・m { 12.8 kgf・m / 93 lb・ft }
6.6 mm { 0.2598 in }
6.7 mm { 0.2638 in }
6.8 mm { 0.2677 in }
6.9 mm { 0.2717 in }
7.0 mm { 0.2756 in }
7.1 mm { 0.2795 in }
43) Apply BESCO L-2 grease or equivalent to the seal
ring.
44) Install the seal ring to the input shaft.

48) Install the input shaft bearing to the input shaft

using a brass rod.

1. Seal ring

45) Install the differential lock clutch to the input shaft.

49) Temporarily tighten the bearing retainer to the

power divider case by inserting 2 shims.
Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft }
50) Measure the bearing end play using a dial gauge.
Bearing end play
Standard value
0.02 to 0.13 mm { 0.0008 to 0.0051 in }

46) Apply FMD127 or equivalent to the differential

carrier.
 Differentials 3B-91

1. Dial gauge 1. Power divider case

2. Bearing retainer 2. Shim
3. Shim 3. LOCTITE application area
4. Power divider case
53) Apply LOCTITE 962T or equivalent to the bearing
Caution： retainer.
・ When the measured bearing end play is 54) Install the bearing retainer and shim to the power
outside the specified range, make adjustments divider case.
by changing the thickness of the shim.
Tightening torque: 98 N・m { 10.0 kgf・m / 72 lb・ft }
Applicable shim thicknesses
0.3 mm { 0.0118 in }
0.4 mm { 0.0157 in }
0.5 mm { 0.0197 in }
1.0 mm { 0.0394 in }
51) Remove the bearing retainer and shim from the
power divider case.
52) Apply LOCTITE 962T or equivalent to the shim
and power divider case.
Caution：
・ Apply LOCTITE or equivalent while avoiding
the oil hole of the power divider case.

1. Bearing retainer
2. Shim

55) Apply LOCTITE 242 or equivalent to the outer

circumference of the oil seal.
56) Apply BESCO L-2 grease or equivalent to the oil
seal lip section.
57) Install the oil seal to the power divider case using a
rubber hammer, etc.
3B-92 Differentials

58) Apply BESCO L-2 grease or equivalent to the O- 1. Inside of the oil pump
ring. 2. Mounting surface of the oil pump
59) Install the O-ring to the input shaft. 65) Install the following parts to the power divider case.
60) Install the flange to the input shaft. ・ Spring
Tightening torque: 686 N・m { 70.0 kgf・m / 506 lb・ ・ Strainer
ft } ・ O-ring
・ Strainer plug
Tightening torque: 69 N・m { 7.0 kgf・m / 51 lb・ft }
6. Inter axle differential lock shift unit installation
1) Apply FMD127 or equivalent to the installation
surface of the differential lock shift unit.
2) Install the differential lock shift unit to the power
divider case.
Tightening torque: 50 N・m { 5.1 kgf・m / 37 lb・ft }
3) Check the operation of the differential lock by
injecting air to the differential lock shift unit.
4) Remove the lock nut and apply LOCTITE 242 or
equivalent to the threaded portion.
Note：
・ Check the operation of the differential lock.

1. O-ring Caution：
・ Turn the set bolt in the tightening direction,
61) Crimp the flange nut. without any grease from the differential lock
Caution： cylinder adhering to the threaded portion.
・ Make sure to stake the 2 places securely. 5) Screw in the set bolt by hand until it stops.
62) Add differential oil to the oil pump. 6) Use the tool to screw the set bolt in further.
63) Apply FMD127 or equivalent to the installation Set bolt screw-in
surface of the oil pump. Standard value
64) Install the oil pump to the power divider case. 60 to 120 °

Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft } 7) Secure the set bolt by tightening the lock nut.
 Differentials 3B-93

1. External air source

2. Differential lock shift unit
3. Tool
4. Set bolt
3B-94 Differentials

installation 1. Component views

Rear differential (Tandem)

Part name
1. Filler plug
2. Drain plug
3. Final drive
4. Strainer plug

Tightening torque
1: 69 N・m { 7.0 kgf・m / 51 lb・ft }
2: 69 N・m { 7.0 kgf・m / 51 lb・ft }
3: 219 N・m { 22.3 kgf・m / 162 lb・ft }
4: 69 N・m { 7.0 kgf・m / 51 lb・ft }
2. Final drive installation
1) Clean the bolts and the rear axle case.
Note：
・ Clean any LOCTITE remaining on the re-used 1. Bolt hole
bolts and the screw holes. 2. Rear axle case differential carrier installation
・ Clean the bolts with the die and the screw hole surface
with the tap as necessary.
4) Install the final drive to the rear axle case.
2) Apply LOCTITE 242 or equivalent to the threaded
portion of the bolt. Tightening torque: 219 N・m { 22.3 kgf・m / 162 lb・
ft }
3) Apply LOCTITE FMD127 or equivalent to the rear
axle case differential carrier installation surface. 3. Output shaft installation
1) Install the outer race of the inner side to the axle
case using a brass rod, etc.
2) Install the inner bearing and outer bearing to the
output shaft.
 Differentials 3B-95
Caution：
・ When the measured output shaft end play is
outside the standard range, make adjustments
by changing the thickness of the spacer.
Thickness of applicable spacer
4.5 mm { 0.177 in }
4.6 mm { 0.181 in }
4.7 mm { 0.185 in }
4.8 mm { 0.189 in }
4.9 mm { 0.193 in }
5.0 mm { 0.197 in }
5.1 mm { 0.201 in }
5.2 mm { 0.205 in }
5.3 mm { 0.209 in }
5.4 mm { 0.213 in }
1. Inner bearing outer race 7) Remove the flange and flange nut from the output
shaft.
3) Install the output shaft to the axle case by aligning
8) Apply LOCTITE 242 or equivalent to the outer
the differential lock collar and spline of the shaft.
circumference of the oil seal.
4) Install the spacer to the output shaft and secure with
9) Install the oil seal to the axle case.
the snap ring.
5) Install the flange and flange nut to the output shaft.
Tightening torque: 373 N・m { 38.0 kgf・m / 275 lb・
ft }
6) Measure the output shaft end play using a dial
gauge.
Output shaft end play
Standard value
0.02 to 0.13 mm { 0.0008 to 0.0051 in }

1. Outer circumference of the oil seal

10) Apply BESCO L-2 grease or equivalent to the O-

ring.
Note：
・ BESCO L-3 grease or equivalent can be
applied.
11) Install the flange and O-ring to the output shaft.
Note：
1. Spacer ・ Tighten until the differential lock is engaged.
Tightening torque: 373 N・m { 38.0 kgf・m / 275 lb・
ft }
3B-96 Differentials
12) Crimp the flange nut. Caution：
・ Do not allow foreign material such as grease,
oil, or paint to attach to the installation
surfaces.
2) Install the propeller shaft between the axles to the
vehicle.
Tightening torque: 103 N・m { 10.5 kgf・m / 76 lb・ft }
3) If the needle bearing is secured using wires when
assembling, remove the wires from the spider.
7. Propeller shaft installation
Caution：
・ Install according to the alignment marks
placed during removal.
1) Clean the flange yoke and flange installation
surfaces so that no grease, oil, paint, or other
foreign material is present.
4. Rear axle shaft installation
1) Install the rear axle shaft to the rear axle.
Tightening torque: 182 N・m { 18.6 kgf・m / 134 lb・
ft }

2) Install the propeller shaft to vehicle.

Note：
・ Install in order starting from the front of the
vehicle and moving rearward.
5. Nylon tube air hose connect ・ When installing the center bearing assembly,
temporarily tighten to the vehicle, and then
1) Connect the nylon tube air hose to the inter-axle final tighten after adjusting the center bearing
differential lock shift unit. assembly mounting section so that it is level
6. Propeller shaft between tandem axles installation with the frame using the oblong holes.
Caution： ・ If the center bearing assembly mounting bolts
and nuts of P90HS are M16 x 1.5, install the
・ Install according to the alignment marks
cotter pins to the nuts.
placed during removal.
・ When installing the cotter pin, if the nut groove
1) Clean the mounting surfaces of the flange yoke and and hole do not align, tighten further and align
flange. at an angle of 30° or less.
206 N・m { 21.0
Transmission flange
kgf・m / 152 lb・ft }
 Differentials 3B-97

186 N・m { 19.0 Center bearing flange (Propeller shaft with center
Center bearing
kgf・m / 137 lb・ft } bearing)
206 N・m { 21.0
Center bearing flange
kgf・m / 152 lb・ft }
206 N・m { 21.0
Axle flange
kgf・m / 152 lb・ft }

Transmission flange

Axle flange

Center bearing (Propeller shaft with center bearing)

3) Lubricate the propeller shaft.

4) Install the propeller shaft guard to the vehicle if one
exists.
Tightening torque: 48 N・m { 4.9 kgf・m / 35 lb・ft }
8. Differential oil filling
1. Differential oil amount and brand
For the differential oil refill amount, refer to the
following.
Refer to "[Link], Axle [Link]
Information Primary specifications of driveline, axle".
For the differential oil brand, refer to the following.
Refer to "[Link] Information [Link]
Information Recommended fluids, lubricants and diesel
fuels".
3B-98 Differentials
2. Differential oil refill procedure (Rear differential Tightening torque: 69 N・m { 7.0 kgf・m / 51 lb・ft }
[Tandem])
9. Preliminary and post procedures
1) Install the drain plug to the rear axle case.
1. Post procedures
Tightening torque: 69 N・m { 7.0 kgf・m / 51 lb・ft }
1) Lower the vehicle.
2) Install the strainer plug to the power divider case.
Tightening torque: 69 N・m { 7.0 kgf・m / 51 lb・ft }

1. Strainer plug
2. Spring
3. Oil strainer

3) Add differential oil to the rear axle case.

Note：
・ Adjust the oil amount to the filler plug hole
brim.

1. Filler plug hole

4) Install the filler plug to the rear axle case.

 Differentials 3B-99

Inter axle differential lock shift unit (17.5HT)

removal 1. Component views

inter axle differential lock shift unit (17.5HT)

Part name bleed the air in the air tank when removing any
1. Cylinder parts in the air piping.
2. Cover bolt 3. Air tank air bleed
3. Cylinder cover
4. Cover gasket 1) Apply chock blocks to the tires.
5. Return spring 2) Discharge air from the air tank by opening the air
6. Shift rod tank drain plug.
7. Shift fork
8. Piston 4. Preliminary and post procedures
9. Piston gasket 1. Preliminary procedures
10. Set bolt
11. Lock nut 1) Raise the vehicle.
5. Nylon tube air hose disconnect
Tightening torque
1) Disconnect the nylon tube air hose from the inter-
1: 13 N・m { 1.3 kgf・m / 115 lb・in } axle differential lock shift unit.
2: 88 N・m { 9.0 kgf・m / 65 lb・ft } 6. Inter axle differential lock shift unit removal
2. Air piping safety information 1) Remove the differential lock shift unit from the
Caution： power divider case.
・ Because high pressure air can burst out and
possibly cause injury, make sure to completely
3B-100 Differentials

disassembly 1. Component views

inter axle differential lock shift unit (17.5HT)

Part name
1. Cylinder
2. Cover bolt
3. Cylinder cover
4. Cover gasket
5. Return spring
6. Shift rod
7. Shift fork
8. Piston
9. Piston gasket
10. Set bolt
11. Lock nut

Tightening torque
1: 13 N・m { 1.3 kgf・m / 115 lb・in }
2: 88 N・m { 9.0 kgf・m / 65 lb・ft }
2. Inter axle differential lock shift unit disassembly 2) Remove the return spring from the cylinder.
1) Remove the cylinder cover and cover gasket from 3) Remove the shift rod from the piston, using a
the cylinder. wrench.
Note：
・ Remove, while preventing rotation by applying
a wrench to both flats of the piston.
 Differentials 3B-101

4) Remove the shift fork and piston from the cylinder.

5) Remove the piston gasket from the piston.
3B-102 Differentials

inspection Return spring tension

Standard value Limit
1. Inter axle differential lock shift unit inspection 363 N { 37.0 kg / 82 lb } 314 N { 32.0 kg / 71 lb }
1. Visual inspection
1) Inspect the cylinder cover and shift rod sliding
surface for the following.
・ Significant wear
・ Damage

3. Measurement of shift fork tip sliding surface

thickness
1) Measure the thickness of the shift fork tip sliding
surface.
Thickness of the tip sliding surface
2) Inspect the return spring for the following. Standard value Limit
・ Rust 12 mm { 0.4724 in } 11 mm { 0.4331 in }
3) Inspect the piston and cylinder sliding surface for
the following.
・ Significant wear
・ Damage

4. Inspection of cylinder air passage

1) Inspect the cylinder air passage for clogging.

2. Measurement of return spring tension

1) Measure the return spring tension.
Differentials 3B-103
3B-104 Differentials

reassembly 1. Component views

inter axle differential lock shift unit (17.5HT)

Part name 2) Apply BESCO ONE LUBER MO grease or

equivalent to the piston gasket and piston top
1. Cylinder
surface.
2. Cover bolt
3. Cylinder cover Standard value
4. Cover gasket 3.0 g { 0.106 oz }
5. Return spring
6. Shift rod 3) Install the piston to the cylinder.
7. Shift fork
8. Piston
9. Piston gasket
10. Set bolt
11. Lock nut

Tightening torque
1: 13 N・m { 1.3 kgf・m / 115 lb・in }
2: 88 N・m { 9.0 kgf・m / 65 lb・ft }
2. Inter axle differential lock shift unit reassembly
1) Install the piston gasket to the piston.
Caution：
・ Do not reuse the gasket.
 Differentials 3B-105
4) Apply LOCTITE 242 or equivalent to the threaded 10) Apply BESCO ONE LUBER MO grease or
portion of the bolt. equivalent to the following areas.
5) Install the shift fork and shift rod to the piston. ・ Inner circumferential surface of the cylinder
cover
Note：
・ Contact surface of the cylinder cover
・ The shift fork is installed with the offset facing ・ Outer circumferential surface of the shift rod
the piston side.
Standard value
1.0 g { 0.035 oz }
11) Apply LOCTITE 242 or equivalent to the threaded
portion of the bolt.
12) As shown in the following diagram, install the
cylinder cover to the differential lock unit so the air
bleeding hole of the cover is on the opposite side of
the piping connector.
Tightening torque: 13 N・m { 1.3 kgf・m / 115 lb・in }

6) Apply LOCTITE 242 or equivalent to the threaded

portion of the bolt.
7) Install the shift rod to the piston.
Tightening torque: 88 N・m { 9.0 kgf・m / 65 lb・ft }

1. Grease application
2. Connector
3. Air bleeding hole

8) Install the return spring to the shift rod.

9) Install the cover gasket to the differential lock shift
unit.
Caution：
・ Do not reuse the gasket.
3B-106 Differentials

13) Install the set bolt and lock nut to the differential
lock shift unit.
 Differentials 3B-107

installation 1. Component views

inter axle differential lock shift unit (17.5HT)

Part name 3) Check the operation of the differential lock by

injecting air to the differential lock shift unit.
1. Cylinder
2. Cover bolt 4) Remove the lock nut and apply LOCTITE 242 or
3. Cylinder cover equivalent to the threaded portion.
4. Cover gasket
Note：
5. Return spring
6. Shift rod ・ Check the operation of the differential lock.
7. Shift fork Caution：
8. Piston
・ Turn the set bolt in the tightening direction,
9. Piston gasket
without any grease from the differential lock
10. Set bolt
cylinder adhering to the threaded portion.
11. Lock nut
5) Screw in the set bolt by hand until it stops.
Tightening torque
6) Use the tool to screw the set bolt in further.
1: 13 N・m { 1.3 kgf・m / 115 lb・in }
Set bolt screw-in
2: 88 N・m { 9.0 kgf・m / 65 lb・ft } Standard value
2. Inter axle differential lock shift unit installation 60 to 120 °
1) Apply FMD127 or equivalent to the installation 7) Secure the set bolt by tightening the lock nut.
surface of the differential lock shift unit.
2) Install the differential lock shift unit to the power
divider case.
Tightening torque: 50 N・m { 5.1 kgf・m / 37 lb・ft }
3B-108 Differentials

1. External air source

2. Differential lock shift unit
3. Tool
4. Set bolt

3. Nylon tube air hose connect

1) Connect the nylon tube air hose to the inter-axle
differential lock shift unit.
4. Preliminary and post procedures
1. Post procedures
1) Lower the vehicle.
 Differentials 3B-109

Differential oil

replacement 1. Strainer plug

2. Drain plug
1. Differential oil drain
2. Differential oil filling
1. Rear differential (Single)
1. Differential oil amount and brand
Move the vehicle to a flat surface, and pull the parking
lever. For the differential oil refill amount, refer to the
following.
1) Raise the vehicle.
Refer to "[Link], Axle [Link]
Note： Information Primary specifications of driveline, axle".
・ Jack up until all tires are off the ground
completely. For the differential oil brand, refer to the following.

2) Remove the filler plug from the rear axle case. Refer to "[Link] Information [Link]
Information Recommended fluids, lubricants and diesel
3) Remove the drain plug from the rear axle case, and fuels".
drain the differential oil.
2. Differential oil refill procedure (Rear differential
Caution： [single])
・ Do not reuse the O-ring. 1) Install the drain plug to the rear axle case.
2. Rear differential (Tandem) Tightening torque: 69 N・m { 7.0 kgf・m / 51 lb・ft }
Move the vehicle to a flat surface, and pull the parking 2) Add differential oil to the rear axle case.
lever.
1) Raise the vehicle.
Note：
・ Jack up until all tires are off the ground
completely.
2) Remove the drain plug from the rear axle case, and
drain the differential oil.
3) Remove the strainer plug from the power divider
case, and drain the differential oil.
Caution：
・ Do not reuse the O-ring.

1. Filler plug hole

3) Install the filler plug to the rear axle case.

Tightening torque: 69 N・m { 7.0 kgf・m / 51 lb・ft }
4) Lower the vehicle.
3. Differential oil refill procedure (Rear differential
[Tandem])
1) Install the drain plug to the rear axle case.
Tightening torque: 69 N・m { 7.0 kgf・m / 51 lb・ft }
2) Install the strainer plug to the power divider case.
Tightening torque: 69 N・m { 7.0 kgf・m / 51 lb・ft }
3B-110 Differentials

1. Strainer plug
2. Spring
3. Oil strainer

3) Add differential oil to the rear axle case.

Note：
・ Adjust the oil amount to the filler plug hole
brim.

1. Filler plug hole

4) Install the filler plug to the rear axle case.

Tightening torque: 69 N・m { 7.0 kgf・m / 51 lb・ft }
5) Lower the vehicle.
 Differentials 3B-111

Supplementary Information
1. Component views

Rear differential (Single)

Part name 1: 69 N・m { 7.0 kgf・m / 51 lb・ft }

1. Filler plug 2: 69 N・m { 7.0 kgf・m / 51 lb・ft }
2. Drain plug
3: 219 N・m { 22.3 kgf・m / 162 lb・ft }
3. Final drive

Tightening torque
3B-112 Differentials

Rear final drive (Single) (17.5H, 18.5H)

Part name 13. Lock washer (Except 18.5H)

14. Adjust nut
1. Drive pinion
15. Side bearing
2. Retainer
16. Differential cage
3. Pilot bearing
4. Retainer Tightening torque
5. Snap ring
6. Cotter pin 1: 402 N・m { 41.0 kgf・m / 296 lb・ft }
7. Shim 2: 20 N・m { 2.0 kgf・m / 15 lb・ft } 17.5H
8. Differential carrier
9. Adjust nut 2: 26 N・m { 2.7 kgf・m / 19 lb・ft } 18.5H
10. Side bearing 3: 13 N・m { 1.3 kgf・m / 115 lb・in }
11. Bearing cap
12. Lock plate 4: 185 N・m { 18.9 kgf・m / 136 lb・ft }
 Differentials 3B-113

Rear drive pinion (Single) (17.5H, 18.5H)

Part name 8. Pinion cage

9. Inner bearing
1. Flange nut
10. Drive pinion
2. O-ring
11. Pilot bearing
3. Flange
12. Snap ring
4. Oil seal
5. Outer bearing Tightening torque
6. Spacer
7. Shim 1: 834 N・m { 85.0 kgf・m / 615 lb・ft }
3B-114 Differentials

Rear differential cage (Single) (17.5H, 18.5H)

Part name 8. Spider

9. Differential cage B and ring gear
1. Differential cage A
2. Side gear thrust washer Tightening torque
3. Side gear
4. Pinion gear thrust washer 1: 206 N・m { 21.0 kgf・m / 152 lb・ft }
5. Pinion gear 2: 431 N・m { 43.9 kgf・m / 318 lb・ft }
6. Side gear
7. Side gear thrust washer
 Differentials 3B-115

Rear differential (Tandem)

Part name 1: 69 N・m { 7.0 kgf・m / 51 lb・ft }

1. Filler plug 2: 69 N・m { 7.0 kgf・m / 51 lb・ft }
2. Drain plug
3: 219 N・m { 22.3 kgf・m / 162 lb・ft }
3. Final drive
4. Strainer plug 4: 69 N・m { 7.0 kgf・m / 51 lb・ft }

Tightening torque
3B-116 Differentials

Rear final drive (Tandem) (17.5HT)

Part name 18. Nut

19. O-ring
1. Oil pickup
20. Flange
2. Differential carrier
21. Oil seal
3. Adjust nut
22. Bearing retainer
4. Side bearing
23. Shim
5. Differential
24. Input shaft bearing
6. Bearing cap
25. Power divider case
7. Lock plate
26. Seal ring
8. Lock washer
27. Differential lock switch
9. Adjust nut
28. Input shaft
10. Side bearing
29. Plug
11. Input shaft bearing
30. Thrust washer
12. Oil catcher
31. Input shaft bearing
13. Side gear
32. Driven helical gear
14. Spacer
33. Snap ring
15. Needle bearing
34. Spider
16. Snap ring
35. Differential cage
17. Thrust washer
 Differentials 3B-117
36. Pinion gear thrust washer 3: 20 N・m { 2.0 kgf・m / 15 lb・ft }
37. Pinion gear
4: 51 N・m { 5.2 kgf・m / 38 lb・ft }
38. Inter-axle differential lock shift unit
39. Spring 5: 50 N・m { 5.1 kgf・m / 37 lb・ft }
40. Strainer
6: 13 N・m { 1.3 kgf・m / 115 lb・in }
41. Oil pump assembly
42. Drive pinion assembly 7: 185 N・m { 18.9 kgf・m / 136 lb・ft }
43. Shim 8: 69 N・m { 7.0 kgf・m / 51 lb・ft }
44. Retainer
45. Snap ring 9: 18 N・m { 1.8 kgf・m / 13 lb・ft }
46. Cotter pin 10: 686 N・m { 70.0 kgf・m / 506 lb・ft }
47. Pilot bearing
11: 98 N・m { 10.0 kgf・m / 72 lb・ft }
Tightening torque
12: 25 N・m { 2.5 kgf・m / 18 lb・ft }
1: 26 N・m { 2.7 kgf・m / 19 lb・ft }
2: 402 N・m { 41.0 kgf・m / 296 lb・ft }

Rear drive pinion (Tandem) (17.5HT)

Part name 7. Inner bearing

8. Drive pinion
1. Pinion nut
9. Pilot bearing
2. Driven helical gear
10. Snap ring
3. Outer bearing
4. Pinion cage Tightening torque
5. Shim
6. Spacer 1: 834 N・m { 85.0 kgf・m / 615 lb・ft }
3B-118 Differentials

Rear differential cage (Tandem) (17.5HT)

Part name 8. Spider

9. Differential cage B and ring gear
1. Differential cage A
2. Side gear thrust washer Tightening torque
3. Side gear
4. Pinion gear thrust washer 1: 206 N・m { 21.0 kgf・m / 152 lb・ft }
5. Pinion gear 2: 431 N・m { 43.9 kgf・m / 318 lb・ft }
6. Side gear
7. Side gear thrust washer
 Differentials 3B-119

inter axle differential lock shift unit (17.5HT)

Part name
1. Cylinder
2. Cover bolt
3. Cylinder cover
4. Cover gasket
5. Return spring
6. Shift rod
7. Shift fork
8. Piston
9. Piston gasket
10. Set bolt
11. Lock nut

Tightening torque
1: 13 N・m { 1.3 kgf・m / 115 lb・in }
2: 88 N・m { 9.0 kgf・m / 65 lb・ft }
Published: Jun., 2017
1st Edition All rights reserved.

'17
WORKSHOP MANUAL
Differentials

Issued by ISUZU MOTORS LIMITED

Service Technical & Training Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan