DIFFERENTIAL CARRIER ASSEMBLY (for 4 Pinion Gear Type) DISASSEMBLY


  1. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY

  2. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR

    A01KF1CE15

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

      Maximum runout
      Runout Maximum
      Vertical runout 0.10 mm (0.0039 in.)
      Lateral runout 0.15 mm (0.0056 in.) or less

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

  3. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

    A01KI0H

    1. Using a dial indicator, measure the runout of the ring gear.

      Maximum runout
      0.01 mm (0.00039 in.)

      • If the runout is greater than the maximum, replace the ring gear with a new one.

  4. INSPECT DIFFERENTIAL RING GEAR BACKLASH

    A01KHZU

    1. Using a dial indicator, measure the backlash of the ring gear.

      Standard backlash
      0.15 to 0.20 mm (0.0059 to 0.0079 in.)

      • If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

        Tech Tips

        Perform the measurements at 3 or more positions around the side bearing preload.

  5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

    A01KFSWE01

    1. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.

      Preload (at starting)
      1.00 to 2.76 N*m (10 to 28 kgf*cm, 8.9 to 24 in.*lbf)

  6. INSPECT TOTAL PRELOAD


    1. Using a torque wrench, measure the total preload.

      Total preload (at starting)
      Drive pinion preload plus 0.20 to 0.39 N*m (2.0 to 3.0 kgf*cm, 1.8 to 3.5 in.*lbf)

  7. REMOVE REAR DRIVE PINION NUT


    1. Using a chisel and a hammer, unstake the staked part of the nut.

    2. A01KF2HE03

      Using SST to hold the flange, remove the nut and washer.

      SST
      09330-00021

  8. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    A01KEOVE04

    1. Using SST, remove the companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040 )

  9. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

    A01KHYME02

    1. Using SST and a press, remove the dust deflector.

      SST
      09950-60010
      09950-70010   ( 09951-07150 )
      09950-00020   ( 09951-00480 )

  10. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

    A01KI1OE02

    1. Using SST, remove the oil seal from the differential carrier.

      SST
      09308-10010

  11. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  12. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    A01KGY7E01

    1. Using SST, remove the rear drive pinion tapered roller bearing from the drive pinion.

      SST
      09556-22010

    2. Remove the rear differential drive pinion spacer adjust shim FR and differential oil storage ring.

  13. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK

    A01KG2FE02

    1. Remove the 2 bolts and rear differential bearing adjust locks.

  14. REMOVE DIFFERENTIAL CASE ASSEMBLY

    A01KG3ME05
    Text in Illustration
    *a Matchmark

    1. Place matchmarks on the bearing cap and differential carrier.

    2. Remove the 4 bolts and 2 differential bearing caps.

    3. Remove the 2 rear differential bearing adjusting nuts.

    4. A01KEUQ

      Remove the rear differential case assembly and 2 bearring outer races from the differential carrier.

      Tech Tips

      Tag the 2 bearing outer races to show the location for reassembling.

  15. REMOVE DIFFERENTIAL DRIVE PINION


    1. A01KEX6E01

      Remove the differential drive pinion from the differential carrier.

  16. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    A01KFAXE01

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

      SST
      09950-00020

      Tech Tips

      If the drive pinion or ring gear are damaged, replace them as a set.

  17. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    A01KIJ4

    1. Using SST, remove the roller bearing (outer) from the carrier.

      SST
      09308-00010

    2. Using a brass bar and a hammer, tap out the oil storage ring from the carrier.

      Tech Tips

      If the bearing is damaged during removal, replace it.

  18. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    A01KFND

    1. Using a brass bar and a hammer, remove the rear tapered roller bearing (outer race) from the carrier.

  19. REMOVE DIFFERENTIAL RING GEAR

    A01KIOXE03
    Text in Illustration
    *a Matchmark

    1. Place matchmarks on the ring gear and differential case.

    2. Using a screwdriver and a hammer, pry out the lock plates.

    3. Remove the 12 ring gear set bolts and 6 rear differential ring gear plate.

    4. A01KIQA

      Using a plastic hammer, tap on the ring gear to separate it from the differential case.

  20. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT

    A01KF1OE01

    1. Install the rear differential case bearing to the differential case.

    2. Install the differential case to the differential carrier.

    3. Install the rear differential cap and 4 bolts to the differential carrier.

      Torque:
      196 N*m  { 2000 kgf*cm, 146 ft.*lbf }

    4. Inspect the differential case runout.

      Maximum runout
      0.05 mm (0.002 in.)

    5. Remove the differential case.

    6. Remove the rear differential case bearing.

  21. REMOVE REAR DIFFERENTIAL CASE BEARING

    A01KFLAE02

    1. Using SST, remove the rear differential case bearing (LH) from the differential case.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00480 )
    2. A01KEIUE02

      Using SST, remove the rear differential case bearing (RH) from the differential case.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00480 )

  22. DISASSEMBLE DIFFERENTIAL CASE

    A01KIHLE05
    Text in Illustration
    *a Matchmark

    1. Place matchmarks on the LH and RH cases.

    2. Remove the 12 bolts.

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

    4. A01KIN4E02
      Text in Illustration
      *1 Differential side gear
      *2 Rear differential side gear thrust washer
      *3 Rear differential spider
      *4 Differential pinion
      *5 Rear differential pinion thrust washer

      Remove these parts from the differential case.

  23. INSPECT DIFFERENTIAL PINION AND SIDE GEAR


    1. Check that no damage is identified on the differential pinion and differential side gear.


      • If the differential pinion and/or differential side gear is damaged, replace the differential.

  24. INSPECT DIFFERENTIAL CASE


    1. Check that no damaged is differential case.


      • If the differential case is damaged, replace the differential case.