DIFFERENTIAL CARRIER ASSEMBLY (for Ring Gear Size 9.5 inch) DISASSEMBLY


  1. FIX DIFFERENTIAL CARRIER ASSEMBLY REAR

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


    1. A01KF1CE06

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

      Maximum runout
      0.1 mm (0.0039 in.)

  3. INSPECT DIFFERENTIAL RING GEAR RUNOUT


    1. A01KEJI

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

      Maximum runout
      0.05 mm (0.0020 in.)

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

  4. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01KEYQ

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

      Backlash
      0.13 to 0.18 mm (0.0051 to 0.0071 in.)

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

  5. INSPECT DRIVEN PINION PRELOAD


    1. A01KFSW

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

      Torque:
      Preload (at starting)
      0.64 to 0.92 N*m  { 6.5 to 9.4 kgf*cm, 5.6 to 8.2 in.*lbf }

  6. INSPECT TOTAL PRELOAD


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

      Torque:
      Total preload (at starting)
      Drive pinion preload plus
      0.38 to 0.63 N*m  { 3.9 to 6.4 kgf*cm, 3.4 to 5.6 in.*lbf }

  7. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR


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

    2. A01KF2HE05

      Using SST to hold the flange, remove the nut.

      SST
      09330-00021
    3. A01KEOVE04

      Using SST, remove the companion flange.

      SST
      09330-00021
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030 )

  8. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01KI1OE02

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

      SST
      09308-10010

  9. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  10. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01KGY7E04

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

      SST
      09556-22010

  11. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A01KFN0E01
      Text in Illustration
      *a Matchmark

      Remove the 2 bolts and rear differential bearing adjust locks.

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

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

    4. Remove the 2 rear differential bearing adjusting nuts.

    5. A01KIFN

      Remove the rear differential case sub-assembly and 2 bearing outer races from the differential carrier.

      Tech Tips

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

  12. REMOVE DIFFERENTIAL DRIVE PINION


    1. A01KEX6

      Remove the differential drive pinion from the differential carrier.

  13. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

  14. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01KFAXE01

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

  15. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01KFRH

      Using a brass bar and a hammer, remove the front bearing (outer race) from the carrier.

  16. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01KFLV

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

  17. REMOVE DIFFERENTIAL RING GEAR


    1. A01KEZYE01
      Text in Illustration
      *a Matchmark

      Place matchmarks on the ring gear and differential case.

    2. Using a screwdriver and a hammer, unstake the 4 lock plates.

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

    4. A01KGH7

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

  18. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. A01KFLAE03

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

      SST
      09950-60010   ( 09951-00440 )
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
    2. A01KEIUE02

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

      SST
      09950-60010   ( 09951-00440 )
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )

  19. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. Place matchmarks on the LH and RH cases.

    2. Remove the 8 bolts.

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

    4. A01KI7PE07
      Text in Illustration
      *1 Differential side gear (2 pieces)
      *2 Rear differential side gear thrust washer (2 pieces)
      *3 Rear differential spider
      *4 Differential pinion (4 pieces)
      *5 Rear differential pinion thrust washer (4 pieces)

      Remove there parts from the differential case.