REAR DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY


  1. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. A01CIEA

      Fix the differential carrier assembly to the overhaul attachment.

  2. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01CIZL

      Remove the 2 bolts and 2 rear differential bearing adjusting nut locks.

  3. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT


    1. A01CH9GE01

      Put matchmarks on the differential bearing cap and differential carrier.

    2. Remove the 4 bolts, 2 bearing caps and 2 rear differential bearing adjusting nuts.

      Note

      Do not swap bearing caps and carriers as they are manufactured as units.

    3. A01CGVIE01

      Tag the removed parts to show the location for installation.

  4. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01CGSZ

      Using a chain block, remove the rear differential case sub-assembly from the rear differential carrier.

    2. Remove the 2 side bearing outer races.

      Tech Tips

      Tag the removed parts.

  5. REMOVE DRIVE PINION SUB-ASSEMBLY


    1. A01CIS6E01

      Remove the 6 bolts.

    2. Remove the drive pinion sub-assembly, drive pinion cage shim(s) and O-ring from the rear differential carrier assembly.

      Tech Tips

      For easy removal, use a brass bar and hammer.

  6. REMOVE PILOT BEARING OUTER RACE


    1. A01CI9F

      Remove the bolt, nut and 2 bearing retainers.

    2. Remove the pilot bearing outer race from the rear differential carrier.

  7. REMOVE SIDE BEARING INNER RACE


    1. A01CI1DE01

      Using SST, remove the 2 side bearing inner races from the differential case.

      SST
      09950-60020   ( 09951-00680 )
      09950-40011   ( 09957-04010 )
      09950-00020
      09950-00030

      If reusing the bearings, arrange them so that the right and left bearings can be distinguished.

  8. REMOVE RING GEAR


    1. A01CHZLE01

      Put matchmarks on the ring gear and differential case LH.

    2. Using a press to hold the differential case, remove the 16 bolts.

    3. Using a plastic hammer, remove the ring gear to separate it from the differential case.

      Note

      Be careful not to drop the ring gear.

  9. REMOVE DIFFERENTIAL CASE


    1. A01CHTEE01

      Put matchmarks on the differential case LH and differential case RH.

    2. A01CI7X

      Using a press to hold the differential case, remove the 8 bolts.

      Note

      Be careful as the bolts are tightened firmly.

    3. Using a plastic hammer, separate the differential case LH and differential case RH.

  10. REMOVE REAR DIFFERENTIAL SPIDER


    1. A01CIOG

      Remove the rear differential side gear thrust washer and the rear differential side gear.

    2. A01CGS7

      Remove the 4 rear differential pinion thrust washers, 4 rear differential pinions and rear differential spider.

    3. Remove the rear differential side gear thrust washer and side gear.

  11. REMOVE PILOT BEARING INNER RACE


    1. A01CGYL

      Using a snap ring expander, remove the snap ring.

      Note

      When removing the snap ring, use a cloth or equivalent to prevent the snap ring from flying off.

    2. A01CIOYE01

      Using SST, remove the pilot bearing inner race from the differential drive pinion.

      SST
      09950-00030
      09950-00020

  12. REMOVE REAR DRIVE PINION NUT


    1. A01CHCC

      Hold the rear drive pinion companion flange sub-assembly in a vise with aluminum plates in between.

    2. A01CIBZE01

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

      SST
      09930-00010

      Note


      • Be sure to use SST with the tapered end facing the shaft.

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

    3. A01CH18

      Using a deep socket wrench (41 mm), remove the rear drive pinion nut.

      Note

      Ensure that the rear drive pinion nut is completely unstaked when removing it.

  13. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. Remove the companion flange sub-assembly from the differential drive pinion.

      Tech Tips

      If the rear drive pinion companion flange sub-assembly is engaged firmly, lightly tap it to remove using a plastic hammer.

  14. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR


    1. A01CHE4E01

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

      SST
      09950-60010   ( 09951-00610 )
      09950-70010   ( 09951-07100 )
      09950-00020

      Note


      • If it is not necessary to replace, do not remove the rear differential dust deflector.

      • Replace the rear differential dust deflector if it is cracked, damaged, or deformed.

      • Be careful not to drop the rear drive pinion companion flange sub-assembly when removing the dust deflector.

  15. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01CGOYE01

      Using SST, remove the rear differential carrier oil seal.

      SST
      09308-10010

  16. REMOVE DIFFERENTIAL DRIVE PINION


    1. A01CJAP

      Using a press, remove the differential drive pinion from the differential drive pinion bearing cage.

      Note

      Be careful not to drop the drive pinion.

    2. Remove the rear drive pinion front tapered roller bearing from the differential drive pinion bearing cage.

  17. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01CJCM

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

  18. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01CHC8E01

      Using SST and a press, remove the rear drive pinion rear tapered roller bearing.

      SST
      09950-00020

  19. REMOVE FRONT BEARING OUTER RACE


    1. A01CI34

      Using a brass bar and a hammer, tap out the front bearing outer race.

      Note

      Do not damage the inner surface of the cage.

  20. REMOVE REAR BEARING OUTER RACE


    1. A01CGPB

      Using a brass bar and a hammer, tap out the rear bearing outer race.

      Note

      Do not damage the inner surface of the cage.