DIFFERENTIAL CARRIER ASSEMBLY (for Ring Gear Size 8.0 inch) DISASSEMBLY


  1. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. A01KFQ1

      Fix the rear differential carrier assembly to the overhaul attachment.

  2. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE


    1. A01KG6FE01
      Text in Illustration
      *a Vertical Runout
      *b Horizontal Runout

      Using a dial indicator, measure the vertical and horizontal runout of the companion flange.

      Distance from center to runout measurement point
      30 mm (1.18 in.)
      Maximum runout
      Runout Specified Condition
      Vertical runout 0.10 mm (0.00394 in.)
      Horizontal runout 0.10 mm (0.00394 in.)

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

  3. INSPECT DIFFERENTIAL RING GEAR RUNOUT


    1. A01KI0H

      Using a dial indicator, check the runout of the ring gear.

      Maximum runout
      0.07 mm (0.00276 in.)

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

  4. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01KGJI

      Using a dial indicator, check the backlash of the ring gear.

      Standard backlash
      0.13 to 0.18 mm (0.00512 to 0.00708 in.)

      Note

      Measure at 3 or more positions around the circumference of the ring gear.

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

  5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

    A01KFSW

    1. Using a torque wrench, measure the preload.

      Standard preload (at Starting)
      0.56 to 0.85 N*m (6 to 9 kgf*cm, 5 to 7 in.*lbf)

  6. INSPECT TOTAL PRELOAD

    A01KFSW

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

      Standard total preload
      Drive pinion preload + 0.39 to 0.59 N*m (4 to 6 kgf*cm, 3 to 5 in.*lbf)

  7. REMOVE REAR DRIVE PINION NUT


    1. A01KFF4E01

      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.

    2. A01KHQDE01

      Using SST and a socket wrench 30 mm, hold the rear drive pinion companion flange sub-assembly and remove the rear drive pinion nut.

      SST
      09330-00021

  8. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    A01KEP8E01
    Text in Illustration
    *a Turn
    *b Hold

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

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

      Note

      Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

  9. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

    A01KGD8E01

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

      SST
      09950-60010   ( 09951-00380 )
      09950-70010   ( 09951-07150 )
      09950-00020

      Note

      Do not drop the companion flange.

  10. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01KH40E01
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09308-10010

      Note

      Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

  11. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. Remove the rear differential drive pinion oil slinger.

  12. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01KFWGE01
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09556-22010

      Note

      Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

  13. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01KG2F

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

  14. REMOVE DIFFERENTIAL CASE ASSEMBLY

    A01KIIQE01

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

      Text in Illustration
      *a Matchmark

    2. Remove the 4 bolts and 2 bearing caps.

    3. A01KESD

      Remove the rear differential case assembly, 2 bearing outer races and 2 adjusting nuts from the differential carrier.

    4. A01KI5P

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

  15. REMOVE DIFFERENTIAL DRIVE PINION


    1. A01KEX6

      Remove the drive pinion and bearing spacer from the differential carrier.

  16. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01KEG4E01

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

      SST
      09950-00020

      Note

      Do not drop the drive pinion.

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

  17. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER


    1. Remove the plate washer from the drive pinion.

  18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01KFRH

      Using a brass bar and a hammer, tap out the rear drive pinion front tapered roller bearing outer race from the differential carrier.

  19. REMOVE DIFFERENTIAL OIL STORAGE RING


    1. A01KHSF

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

  20. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01KFLV

      Using a brass bar and a hammer, tap out the rear drive pinion rear tapered roller bearing outer race from the differential carrier.

  21. REMOVE DIFFERENTIAL RING GEAR


    1. A01KFQKE01
      Text in Illustration
      *a Matchmark

      Place matchmarks on the ring gear and differential case.

    2. Using a screwdriver and a hammer, unstake 5 ring gear plates.

    3. A01KIJV

      Remove the 10 bolts and 5 ring gear plates.

    4. A01KGH7

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

  22. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT


    1. Install the 2 rear differential case bearing outer races to the differential case.

    2. Install the differential case to the differential carrier.

    3. Install the 2 bearing caps to the differential carrier with the 4 bolts.

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }
    4. A01KEXA

      Using a dial indicator, measure the differential case runout.

      Maximum runout
      0.07 mm (0.00276 in.)

    5. Remove the 4 bolts and 2 bearing caps.

    6. Remove the differential case and 2 bearing outer races from the differential carrier.

  23. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. A01KGEJE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the 2 rear differential case bearings from the differential case.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00360 )

      Note

      Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

      Tech Tips

      Do not remove a case bearing unless replacing the differential case.

  24. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY (for 2 Pinion Gear Type)


    1. Secure the differential case in a vise using aluminum plates.

      Note

      Do not overtighten the vise, as the differential case may become deformed.

    2. A01KIED

      Using a pin punch 5 mm and a hammer, remove the straight pin.

    3. A01KFV0E01
      Text in Illustration
      *1 Rear Differential Pinion
      *2 Rear Differential Pinion Thrust Washer
      *3 Rear Differential Pinion Shaft
      *4 Rear Differential Side Gear
      *5 Rear Differential Side Gear Thrust Washer

      Remove the following parts from the differential case.

  25. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY (for 4 Pinion Gear Type)


    1. Secure the differential case RH in a vise using aluminum plates.

      Note

      Do not overtighten the vise, as the differential case may become deformed.

    2. A01KESPE01
      Text in Illustration
      *a Matchmark

      Place matchmarks on the LH and RH cases.

    3. Remove the 8 bolts.

    4. A01KIBB

      Using a plastic hammer, separate the LH and RH cases.

    5. A01KHFZE01
      Text in Illustration
      *1 Rear Differential Side Gear
      *2 Rear Differential Side Gear Thrust Washer
      *3 Rear Differential Spider
      *4 Rear Differential Pinion
      *5 Rear Differential Pinion Thrust Washer

      Remove the following parts from the differential case.

  26. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY (for LSD)


    1. Secure the differential case RH in a vise using aluminum plates.

      Note

      Do not overtighten the vise, as the differential case may become deformed.

    2. A01KESPE01
      Text in Illustration
      *a Matchmark

      Place matchmarks on the LH and RH cases.

      Note

      Loosen the bolts gradually, always skipping to a diagonally opposite bolt.

    3. Remove the 8 bolts.

    4. A01KFXQE01
      Text in Illustration
      *1 Rear Differential Side Gear
      *2 Rear No. 1 Differential Side Gear Thrust Washer
      *3 Clutch Plate
      *4 Rear Differential Side Gear Thrust Washer
      *5 Spring Retainer RH
      *6 Spring Retainer LH
      *7 Compression Spring
      *8 Rear Differential Pinion
      *9 Rear Differential Pinion Thrust Washer
      *10 Rear Differential Spider

      Remove the following parts from the differential case.