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REAR DIFFERENTIAL CARRIER ASSEMBLY(for 2WD) DISASSEMBLY

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PROCEDURE


  1. Click here

    REMOVE REAR DIFFERENTIAL DYNAMIC DAMPER


    1. B004TET

      Using a 12 mm hexagon wrench, remove the bolt and rear differential dynamic damper from the rear differential carrier cover.

  2. Click here

    REMOVE REAR DIFFERENTIAL BREATHER PLUG


    1. B004UB1

      Remove the rear differential breather plug from the rear differential carrier cover.

  3. Click here

    REMOVE REAR DIFFERENTIAL CARRIER COVER


    1. B004S5W

      Remove the 8 bolts.

    2. B004U1Y

      Using a brass bar and hammer, remove the rear differential carrier cover from the rear differential carrier.

      Note:

      • Place the brass bar onto the corners of the rear differential carrier cover.

      • Do not damage the sealing surface of the rear differential carrier.

  4. Click here

    REMOVE REAR DIFFERENTIAL CARRIER STRAIGHT PIN

    Tip:

    It is not necessary to remove a rear differential carrier straight pin unless it is being replaced.


    1. B004RPL

      Remove the 2 rear differential carrier straight pins from the rear differential carrier cover.

  5. Click here

    REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. B004VE8

      Remove the bolt and rear differential breather plug oil deflector from the rear differential carrier cover.

  6. Click here

    SECURE REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. B004RJ7

      Install the rear differential carrier assembly to an overhaul stand as shown in the illustration.

  7. Click here

    INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. B004UE0

      Set a dial indicator perpendicular to the end of the differential ring gear face.

    2. Rotate the differential ring gear and measure the runout.

      Maximum runout
      0.05 mm (0.00197 in.)
      Tip:

      If the runout is more than the maximum, remove the differential ring gear and check the runout of the rear differential case sub-assembly.

  8. Click here

    INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. B004W9V

      While holding the rear drive pinion companion flange, rotate the differential ring gear and measure the backlash.

      Backlash
      0.09 to 0.145 mm (0.00355 to 0.00570 in.)
      Tip:

      If the backlash is not within the specified range, adjust the backlash or perform repairs as necessary.

  9. Click here

    INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. B004WLG

      Coat 3 or 4 teeth at 3 different positions on the differential ring gear with Prussian blue.

    2. Rotate the differential ring gear in both directions.

    3. B004V46C06
      *a Proper Contact *b Heel Contact
      *c Face Contact *d Select an adjusting washer that will shift the drive pinion closer to the ring gear (*b, *c)
      *e Toe Contact *f Flank Contact
      *g Select an adjusting washer that will shift the drive pinion away from the ring gear (*e, *f) - -

      Inspect the tooth contact pattern.

      Note:

      Check the tooth contact pattern at 4 or more positions around the circumference of the differential ring gear.

  10. Click here

    INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. B004T7J

      Place a dial indicator on the tip of a side gear tooth at a right angle. Hold the pinion gear in the rear differential case sub-assembly and check that the backlash is 0 mm (0 in.).

      If the result is not as specified, replace the rear differential case sub-assembly with a new one.

  11. Click here

    INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION


    1. B004XHOC01
      *a 10 mm (0.394 in.)

      Using a dial indicator, measure the runout of the differential drive pinion shaft at a position 10 mm (0.394 in.) away from the end of the shaft.

      Maximum runout
      0.08 mm (0.00315 in.)

      If the runout is more than the maximum, replace the differential drive pinion and differential ring gear.

  12. Click here

    INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. B004UI8N01

      Using SST and a torque wrench, measure the starting torque of the differential drive pinion.

      09229-55010
      Differential drive pinion preload (at starting)
      Item Specified Condition
      New bearing 0.52 to 0.95 N*m (6 to 9 kgf*cm, 0.4 to 0.7 ft.*lbf)
      Reused bearing 0.43 to 0.66 N*m (5 to 6 kgf*cm, 0.32 to 0.48 ft.*lbf)
      Tip:

      • The backlash between the differential drive pinion and differential ring gear should allow enough movement of the differential drive pinion to allow this measurement to be performed.

      • Make sure not to include the preload of the differential ring gear (rear differential case sub-assembly) in the measurement of the differential drive pinion preload.

  13. Click here

    INSPECT TOTAL PRELOAD


    1. B004UI8N01

      Using SST and a torque wrench, measure the preload with the teeth of the differential drive pinion and differential ring gear in contact.

      09229-55010
      Total Preload (at Starting)
      Item Specified Condition
      New bearing 1.0 to 2.0 N*m (11 to 20 kgf*cm, 0.8 to 1.4 ft.*lbf)
      Reused bearing 0.85 to 1.54 N*m (9 to 15 kgf*cm, 0.7 to 1.1 ft.*lbf)
  14. Click here

    REMOVE REAR DRIVE SHAFT OIL SEAL LH


    1. B004SZVC01
      *1 Rear Drive Shaft Oil Seal LH

      Using SST, remove the rear drive shaft oil seal LH.

      09308-00010
  15. Click here

    REMOVE REAR DRIVE SHAFT OIL SEAL RH

    Tip:

    Perform the same procedure as for the LH side.

  16. Click here

    REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING (for RH Side)


    1. B004T7AC01
      *a Disc

      Install SST to the differential carrier with the 2 bolts (A) so that the center of the SST disc is at the center of the rear differential case bearing (outer race).

      09571-10200 09571-01220 09571-01230

    2. Tighten the SST bolt (B) until the SST disc lightly touches the rear differential case bearing outer race on the differential ring gear tooth side.

    3. B004SETC01
      *a Turn

      Install a dial indicator to the rear differential carrier.

      Tip:

      Set the dial indicator as shown in the illustration.

    4. Tighten the SST bolt and alter the shape of the rear differential carrier to create a 0.1 mm (0.00394 in.) clearance between the rear differential case bearing outer race and rear differential side gear shaft snap ring.

      Note:

      Observe the dial indicator to ensure that the shape of the rear differential carrier does not change by more than 0.2 mm (0.00787 in.).

      Tip:

      A clearance of approximately 0.1 mm (0.00394 in.) between the rear differential case bearing outer race RH and rear differential side gear shaft snap ring is sufficient for the rear differential side gear shaft snap ring to move slightly.

    5. B004U1HN01

      Using SST, remove the rear differential side gear shaft snap ring on the differential ring gear tooth side.

      09905-00031
      Tip:

      • For reassembly purposes, measure the thickness of the rear differential side gear shaft snap ring. Write down the result.

      • Put identification marks on each rear differential side gear shaft snap ring on the back side and tooth side of the ring gear, and keep them separate.

    6. B004WFMN01

      Remove the dial indicator and loosen the SST bolt.

      Note:

      Do not remove SST.

  17. Click here

    REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING (for LH Side)


    1. B004T8PN01

      Using SST and a hammer, create a clearance between the rear differential case bearing outer race on the back surface of the differential ring gear and the rear differential side gear shaft snap ring.

      09527-17011
      09950-60020 09951-00810 09951-01030 09952-06010
      09950-70010 09951-07150
      Tip:

      The clearance is not visible, but tapping SST with a hammer 3 or 4 times should be enough.

    2. B004TT8N01

      Using SST, remove the rear differential side gear shaft snap ring on the back surface of the differential ring gear.

      09905-00031
      Tip:

      • For reassembly purposes, measure the thickness of the rear differential side gear shaft snap ring. Write down the result.

      • Put identification marks on each rear differential side gear shaft snap ring on the back side and tooth side of the ring gear, and keep them separate.

  18. Click here

    REMOVE REAR DIFFERENTIAL CASE BEARING (for LH Side)


    1. B004X4KN01

      Tighten the SST bolt and push out the rear differential case bearing (outer race) on the back surface of the differential ring gear.

      09571-10200 09571-01220 09571-01230
      Note:

      Do not drop the rear differential case bearing outer race.

      Tip:

      Put identification marks on the rear differential case bearing outer race and rear differential side gear shaft snap ring to show the location for installation (back side or teeth side), or keep the races and snap rings separate so that they can be distinguished.

    2. B004VDYN01

      Remove the 2 bolts and SST.

  19. Click here

    REMOVE REAR DIFFERENTIAL CASE BEARING (for RH Side)


    1. B004R93

      Raise the differential ring gear side of the rear differential case sub-assembly slightly to remove the rear differential case bearing (outer race) on the differential ring gear tooth side.

      Note:

      Do not drop the rear differential case bearing outer race RH.

      Tip:

      Put identification marks on the rear differential case bearing outer race and rear differential side gear shaft snap ring to show the location for installation (back side or teeth side), or keep the races and snap rings separate so that they can be distinguished.

  20. Click here

    REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. B004SS4

      Remove the rear differential case sub-assembly as shown in the illustration.

      Note:

      Do not damage the rear differential case bearing and differential ring gear.

  21. Click here

    REMOVE REAR DRIVE PINION NUT


    1. B004S85N01

      Using SST and a hammer, unstake the staked part of the rear drive pinion nut.

      09930-00010
      Note:

      • Be sure to use SST with the tapered surface facing the differential drive pinion.

      • Do not grind the tip of SST with a grinder, etc.

      • Completely loosen the staked part of the rear drive pinion nut when removing it.

      • Do not damage the threads of the differential drive pinion.

    2. B004RJ1C01
      *a Turn
      *b Hold

      Using SST to hold the rear drive pinion companion flange, remove the rear drive pinion nut.

      09229-55010
      09330-00021
      09950-30012 09955-03040
      CAUTION:

      Hold the overhaul attachment during the operation.

      Tip:

      When securing SST and the companion flange, it is recommended to use M8 X P 1.25 bolts with a length of approximately 40 mm.

  22. Click here

    REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. B004X94C01
      *a Turn
      *b Hold

      Using SST, remove the rear drive pinion companion flange sub-assembly.

      09950-30012 09951-03010 09953-03010 09954-03010 09955-03040 09956-03060
      Note:

      Apply molybdenum grease to the threads of the SST center bolt (09953-03010) before use.

  23. Click here

    REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

    Tip:

    Perform this procedure only when the rear differential dust deflector is damaged.


    1. B004S2YN02

      Using SST and a press, remove the rear differential dust deflector.

      09555-55010
      09950-60010 09951-00440
      09950-70010 09951-07100
      Note:

      Do not drop the rear drive pinion companion flange.

      Tip:

      Be sure to perform this operation while tightening the SST nuts to protect the contact surface of SST and the rear differential dust deflector.

  24. Click here

    REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

    Click here

  25. Click here

    REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. B004XVH

      Remove the rear differential drive pinion oil slinger.

  26. Click here

    REMOVE DIFFERENTIAL DRIVE PINION


    1. B004XAP

      Using a press, remove the differential drive pinion from the rear differential carrier.

      Note:

      Do not drop the differential drive pinion.

  27. Click here

    REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. B004SM5

      Remove the rear differential drive pinion bearing spacer from the differential drive pinion.

  28. Click here

    REMOVE REAR DRIVE PINION FRONT BEARING


    1. B004R9K

      Remove the rear drive pinion front bearing (inner race) from the rear differential carrier.

    2. B004SVOC02
      *1 Rear Drive Pinion Front Bearing (Outer Race)

      Using SST, remove the rear drive pinion front bearing (outer race) from the rear differential carrier.

      09950-60010 09951-00600
      09950-70010 09951-07200
  29. Click here

    REMOVE REAR DRIVE PINION REAR BEARING


    1. B004WHO

      Remove the 2 rear drive pinion rear bearings (ball bearing).

    2. B004VMRN02

      Using SST and a press, remove the rear drive pinion rear bearing (inner race) from the differential drive pinion.

      09555-55010
      Note:

      Do not drop the differential drive pinion.

      Tip:

      If either the differential drive pinion or differential ring gear is damaged, replace both as a set.

    3. B004UMKC01
      *1 Rear Differential Drive Pinion Plate Washer
      *2 Rear Drive Pinion Rear Bearing (Outer Race)

      Using a brass bar and hammer, remove the rear drive pinion rear bearing (outer race) from the rear differential carrier.

      Tip:

      Set the brass bar onto the concave portion of the differential carrier assembly. Lightly and uniformly tap the bearing and shim to remove them.

    4. Remove the rear differential drive pinion plate washer.

      Tip:

      Make a note of the rear differential drive pinion plate washer thickness as a reference for assembly.

  30. Click here

    REMOVE DIFFERENTIAL OIL STORAGE RING


    1. B004SC9C01
      *1 Differential Oil Storage Ring

      Using SST, remove the differential oil storage ring from the rear differential carrier.

      09308-00010
      Note:

      Do not damage the rear differential carrier.

  31. Click here

    REMOVE DIFFERENTIAL RING GEAR


    1. Hold the rear differential case sub-assembly in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

    2. B004VUFC01
      *a Matchmark

      Put matchmarks on the differential ring gear and rear differential case sub-assembly.

    3. Remove the 12 bolts.

    4. Using a plastic-faced hammer, tap on the differential ring gear to remove it from the rear differential case sub-assembly.

      Tip:

      Place a cloth on the teeth side of the ring gear to prevent damage.

  32. Click here

    INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY

    Tip:

    Perform this procedure only when the runout of the differential ring gear exceeds the specified maximum value.


    1. B004XDE

      Insert the rear differential case sub-assembly from the differential ring gear tooth side to install the rear differential case sub-assembly as shown in the illustration.

      Note:

      Do not damage the rear differential case bearing.

    2. B004X01C01
      *a Groove

      Using SST and a hammer, install the rear differential case bearing (outer race) RH to the differential ring gear tooth side.

      09527-17011
      09950-60020 09951-00810 09951-01030 09952-06010
      09950-70010 09951-07150
      Tip:

      Tap in the rear differential case bearing outer race RH until half of the rear differential side gear shaft snap ring groove of the rear differential carrier can be seen.

    3. B004T5LN01

      Install SST to the differential carrier with the 2 bolts (A) so that the center of the SST disc is at the center of the rear differential case bearing (outer race).

      09571-10200 09571-01220 09571-01230
    4. B004VULC01
      *a Disc

      Tighten the SST bolt (B) until the SST disc lightly touches the rear differential case bearing (outer race) RH.

    5. B004T8PN01

      Using SST and a hammer, install the rear differential case bearing (outer race) LH to the differential ring gear back surface side.

      09527-17011
      09950-60020 09951-00810 09951-01030 09952-06010
      09950-70010 09951-07150
      Tip:

      Tap in the rear differential case bearing outer race LH until it touches the rear differential case bearing inner race roller.

    6. B004TT8N01

      Using SST, install the rear differential side gear shaft snap ring to the rear differential carrier on the differential ring gear back surface side.

      09905-00031
    7. B004R1Z

      Place a dial indicator on the rear differential case sub-assembly flange surface at a right angle.

    8. Using a dial indicator, measure the rear differential case sub-assembly runout.

      Maximum runout
      0.05 mm (0.00197 in.)

      If the runout is more than the maximum, replace the rear differential case sub-assembly with a new one.

    9. B004TT8N01

      Using SST, remove the rear differential side gear shaft snap ring from the differential ring gear back surface side.

      09905-00031
    10. B004UH1C01
      *a Turn

      Tighten the SST bolt to push out the rear differential case bearing (outer race) LH from the back surface of the differential ring gear.

      09571-10200 09571-01220 09571-01230
      Note:

      Do not drop the differential side bearing (outer race) LH.

    11. B004RAAN01

      Remove the 2 bolts and SST.

    12. B004VAI

      Raise the differential ring gear side of the rear differential case sub-assembly slightly to remove the differential side bearing (outer race) RH on the differential ring gear tooth side.

    13. B004X3K

      Remove the rear differential case sub-assembly from the rear differential carrier as shown in the illustration.

      Note:

      Do not damage the rear differential case bearing.

  33. Click here

    REMOVE REAR DIFFERENTIAL CASE BEARING

    Tip:

    Perform this procedure only when replacing the rear differential case bearing or rear differential case sub-assembly.


    1. B004T5SC01
      *a Turn
      *b Hold

      Using SST, remove the rear differential case bearing (inner races) LH and RH from the rear differential case sub-assembly.

      09950-40011 09951-04020 09952-04010 09953-04030 09954-04010 09955-04031 09957-04010 09958-04011
      09950-60010 09951-00540
      Note:

      • Do not deform the bearing cage if the bearing is to be reused.

      • Hook the claws of SST to the rear differential case bearing inner race.

      • Apply molybdenum grease to the threads and tip of the SST center bolt (09953-04030) before use.

  34. Click here

    INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. B004XLP

      Secure the rear differential case sub-assembly in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

    2. Place a dial indicator on the tip of a side gear tooth at a right angle. Hold the pinion gear in the rear differential case sub-assembly and check that the backlash is 0 mm (0 in.).

      If the result is not as specified, replace the rear differential case sub-assembly with a new one.