DIFFERENTIAL CARRIER ASSEMBLY (for 2 Pinion Gear Type) DISASSEMBLY

INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

Text in Illustration
*a	Vertical Runout
*b	Lateral Runout

Using a dial indicator, measure the runout of the companion flange vertically and laterally.

Maximum runout

Runout	Standard Condition
Vertical runout	0.1 mm (0.00394 in.)
Lateral runout	0.1 mm (0.00394 in.)

If the runout is greater than the maximum, replace the companion flange.

INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
1. Using a dial indicator, measure the runout of the ring gear.
  
  Maximum runout
  
  0.05 mm (0.00197 in.)
  
  If the runout is greater than the maximum, replace the ring gear with a new one.
INSPECT DIFFERENTIAL RING GEAR BACKLASH
1. Using a dial indicator, measure the backlash of the ring gear.
  
  Standard backlash
  
  0.10 to 0.20 mm (0.00394 to 0.00788 in.)
  
  Tech Tips
  
  Measure at 3 or more positions around the circumference of the ring gear.
  
  If the backlash is not within the specification, adjust or repair the side bearing preload as necessary.
INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
1. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the case.
  
  Standard backlash
  
  0.15 mm (0.00591 in.) or less
  
  If the backlash is not within the specification, replace the side gear thrust washer with one of a different thickness.
INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
1. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
  
  Standard drive pinion preload (at starting)
  
  1.62 to 2.25 N*m (17 to 22 kgf*cm, 15 to 19 in.*lbf)
  
  If necessary, disassemble and inspect the differential.

Maximum runout
0.05 mm (0.00197 in.)

Standard backlash
0.10 to 0.20 mm (0.00394 to 0.00788 in.)

Standard backlash
0.15 mm (0.00591 in.) or less

Standard drive pinion preload (at starting)
1.62 to 2.25 Nm (17 to 22 kgfcm, 15 to 19 in.*lbf)

INSPECT TOTAL PRELOAD

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

Standard total preload (at starting)
Standard drive pinion preload plus 0.19 to 0.38 Nm (2 to 3 kgfcm, 2 to 3 in.*lbf)

If necessary, disassemble and inspect the differential.

REMOVE REAR DRIVE PINION NUT
1. Using SST and a hammer, unstake the nut.
  
  SST
  
  09930-00010
2. Using SST to hold the companion flange, remove the nut.
  
  SST
  
  09330-00021 ( 09330-00030 )
REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
1. Using SST, remove the companion flange.
  
  SST
  
  09950-30012 ( 09951-03010, 09953-03010, 09954-03010, 09956-03030 )
  
  09955-03050
REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
1. Using SST, remove the oil seal.
  
  SST
  
  09308-10010
REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Using SST, remove the bearing (inner race).
  
  SST
  
  09950-40011 ( 09951-04010, 09953-04020, 09952-04010 )
  
  09955-04130
  
  09958-04020
2. Remove the 2 preload adjusting shims.
REMOVE REAR DIFFERENTIAL CASE ASSEMBLY
1. Text in Illustration
  
  *a Matchmark
  
  Place matchmarks on the bearing cap and differential carrier.
2. Remove the 4 bolts and 2 differential bearing caps.
3. Using SST and a plastic-faced hammer, remove the 2 side bearing plate washers.
  
  SST
  
  09504-22011
  
  Tech Tips
  
  Measure the plate washer thickness and note it down.
4. Remove the differential case with the bearing outer races from the carrier.
  
  Tech Tips
  
  Tag the bearing outer races to show the location for reassembling.
REMOVE REAR DIFFERENTIAL DRIVE PINION
1. Remove the differential drive pinion and bearing spacer from the differential carrier.
REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
1. Using SST and a press, press out the bearing (inner race).
  
  SST
  
  09950-00020
  
  If either the drive pinion or ring gear is damaged, replace them as a set.
REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER
REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Using SST, remove the bearing (outer race).
  
  SST
  
  09308-00010
  
  If the bearing is damaged during removal, replace it.
REMOVE DIFFERENTIAL OIL STORAGE RING
1. Using a brass bar and hammer, tap out the storage ring.
REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
1. Using a brass bar and hammer, tap out the bearing (outer race).
  
  If the bearing is damaged during removal, replace it.
REMOVE DIFFERENTIAL RING GEAR
1. Text in Illustration
  
  *a Matchmark
  
  Place matchmarks on the ring gear and differential case.
2. Remove the 12 ring gear set bolts.
3. Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.
INSPECT REAR DIFFERENTIAL CASE ASSEMBLY RUNOUT
Tech Tips

If the ring gear runout is within the specification (see "INSPECT RUNOUT OF DIFFERENTIAL RING GEAR" procedure), this inspection is not necessary.
1. Install the differential case to the differential carrier.
2. Inspect the differential case runout.
  
  Maximum runout
  
  0.04 mm (0.00158 in.)
3. Remove the differential case from the differential carrier.
REMOVE REAR DIFFERENTIAL CASE BEARING
1. Using SST, remove the 2 bearings.
  
  SST
  
  09950-40011 ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09957-04010, 09958-04011 )
  
  09950-60010 ( 09951-00500 )
  
  09955-04120
  
  Tech Tips
  
  Fix the claws of SST to the notches in the differential case.
DISASSEMBLE DIFFERENTIAL CASE
1. Using a pin punch and hammer, tap out the straight pin.
2. Remove the pinion shaft, 2 pinion gears, 2 pinion gear thrust washers, 2 side gears and 2 side gear thrust washers.
REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
1. Text in Illustration
  
  *1 Steel Plate
  
  When replacing dust reflector:
  
  Using SST, a steel plate and press, press out the dust deflector.
  
  SST
  
  09950-00020
  
  Note
  
  Do not drop the companion flange.