DIFFERENTIAL CARRIER ASSEMBLY (for Ring Gear Size 10.5 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 SUB-ASSEMBLY

    A01KG6FE02
    Text in Illustration
    *a Vertical Runout
    *b Horizontal Runout

    1. Using a dial indicator, measure the vertical and horizontal runout of the rear drive pinion companion flange sub-assembly.

      Distance from center to runout measurement point A
      for 2 Pinion Gear Type
      30 mm (1.18 in.)
      for 4 Pinion Gear Type
      35 mm (1.38 in.)
      Maximum Runout
      Type Runout Standard Condition
      for 2 Pinion Gear Vertical runout 0.10 mm (0.00394 in.)
      Horizontal runout 0.10 mm (0.00394 in.)
      for 4 Pinion Gear Vertical runout 0.10 mm (0.00394 in.)
      Horizontal runout 0.15 mm (0.00590 in.)

      If the runout is greater than the maximum, replace the rear drive pinion companion flange sub-assembly.

  3. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. A01KEKP

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

      Maximum runout
      for 2 Pinion Gear Type
      0.05 mm (0.00197 in.)
      for 4 Pinion Gear Type
      0.01 mm (0.000393 in.)

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

  4. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01KGCZ

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

      Standard backlash
      for 2 Pinion Gear Type
      0.10 to 0.20 mm (0.00394 to 0.00787 in.)
      for 4 Pinion Gear Type
      0.15 to 0.20 mm (0.00591 to 0.00787 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.

  5. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (for 2 Pinion Gear Type)


    1. A01KEZ7

      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.

  6. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01KH8J

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

      Standard drive pinion preload (at starting)
      for 2 Pinion Gear Type
      1.62 to 2.25 N*m (17 to 22 kgf*cm, 15 to 19 in.*lbf)
      for 4 Pinion Gear Type
      1.00 to 2.76 N*m (10 to 28 kgf*cm, 8.9 to 24 in.*lbf)

      If necessary, disassemble and inspect the differential.

  7. INSPECT TOTAL PRELOAD


    1. A01KH8J

      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)
      for 2 Pinion Gear Type
      Standard drive pinion preload + 0.19 to 0.38 N*m (2.0 to 3.8 kgf*cm, 1.7 to 3.3 in.*lbf)
      for 4 Pinion Gear Type
      Standard drive pinion preload + 0.20 to 0.39 N*m (2.1 to 3.9 kgf*cm, 1.8 to 3.4 in.*lbf)

      If necessary, disassemble and inspect the differential.

  8. REMOVE REAR DRIVE PINION NUT (for 2 Pinion Gear Type)

    A01KEM1E01

    1. 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. A01KH2ZE02
      Text in Illustration
      *a Turn
      *b Hold

      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

  9. REMOVE REAR DRIVE PINION NUT (for 4 Pinion Gear Type)

    A01KEM1E01

    1. 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. A01KH2ZE02
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09330-00021

  10. 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.

  11. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

    A01KH40E01
    Text in Illustration
    *a Turn
    *b Hold

    1. 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.

  12. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. Remove the rear differential drive pinion oil slinger.

  13. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (for 2 Pinion Gear Type)

    A01KH6DE02
    Text in Illustration
    *a Turn
    *b Hold

    1. Using SST, remove the rear drive pinion front tapered roller bearing (inner race) from the drive pinion.

      SST
      09950-40011   ( 09951-04010, 09953-04020, 09952-04010 )
      09955-04130
      09958-04020

      Note

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

    2. Remove the 2 preload adjusting shims.

  14. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (for 4 Pinion Gear Type)

    A01KFWGE01
    Text in Illustration
    *a Turn
    *b Hold

    1. Using SST, remove the rear drive pinion front tapered roller bearing (inner race) from the drive pinion.

      SST
      09556-22010

      Note

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

    2. Remove the 2 rear differential drive pinion spacer adjust shims.

  15. REMOVE REAR DIFFERENTIAL CASE ASSEMBLY (for 2 Pinion Gear Type)


    1. A01KF89E02
      Text in Illustration
      *a Matchmark

      Place matchmarks on the bearing cap and the differential carrier.

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

    3. A01KG6ME02

      Using SST and a plastic 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 2 case bearing outer races from the differential carrier.

      Tech Tips

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

  16. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK (for 4 Pinion Gear Type)

    A01KG2FE02

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

  17. REMOVE REAR DIFFERENTIAL CASE ASSEMBLY (for 4 Pinion Gear Type)

    A01KG3ME05

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

      Text in Illustration
      *a Matchmark

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

    3. Remove the 2 rear differential bearing adjusting nuts.

    4. A01KEUQ

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

      Tech Tips

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

  18. REMOVE REAR DIFFERENTIAL DRIVE PINION


    1. A01KEX6

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

  19. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    A01KEG4E01

    1. Using SST and a press, remove the rear drive pinion rear tapered roller bearing (inner race) from the drive pinion.

      SST
      09950-00020

      Tech Tips

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

  20. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER


    1. Remove the plate washer from the drive pinion.

  21. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01KEW7E01

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

      SST
      09308-00010

      Tech Tips

      If the bearing is damaged during removal, replace it.

  22. REMOVE DIFFERENTIAL OIL STORAGE RING


    1. A01KGO6

      Using a brass bar and a hammer, tap out the storage ring.

  23. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01KFRW

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

      Tech Tips

      If the bearing is damaged during removal, replace it.

  24. REMOVE DIFFERENTIAL RING GEAR (for 2 Pinion Gear Type)

    A01KF0TE01
    Text in Illustration
    *a Matchmark

    1. Place matchmarks on the ring gear and the 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.

  25. REMOVE DIFFERENTIAL RING GEAR (for 4 Pinion Gear Type)

    A01KIOXE02

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

      Text in Illustration
      *a Matchmark

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

    3. Remove the 12 ring gear set bolts and the 6 lock plates.

    4. A01KIQA

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

  26. INSPECT REAR DIFFERENTIAL CASE ASSEMBLY RUNOUT

    A01KG4G

    1. Install the differential case to the differential carrier.

    2. Inspect the differential case runout.

      Maximum runout
      for 2 Pinion Gear Type
      0.04 mm (0.00158 in.)
      for 4 Pinion Gear Type
      0.05 mm (0.00197 in.)

    3. Remove the differential case from the differential carrier.

  27. REMOVE REAR DIFFERENTIAL CASE BEARING (for 2 Pinion Gear Type)


    1. A01KGA3E01

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

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00500 )
      09955-04120

      Note

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

      Tech Tips

      Fix the claws of SST to the notches in the differential case.

  28. REMOVE REAR DIFFERENTIAL CASE BEARING (for 4 Pinion Gear Type)

    A01KFLAE02

    1. 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   ( 09951-00480 )

      Note

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

  29. REMOVE DIFFERENTIAL CASE (for 2 Pinion Gear Type)


    1. A01KFJM

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

    2. Remove the pinion shaft, 2 pinion gears, 2 pinion gear thrust washers, 2 side gears and the 2 side gear thrust washers.

  30. REMOVE DIFFERENTIAL CASE (for 4 Pinion Gear Type)

    A01KHFGE01
    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 cases.

    4. A01KHFZE01
      *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 these parts from the differential case.

  31. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR


    1. A01KGD8E01

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

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

      Note

      Do not drop the rear drive pinion companion flange sub-assembly.

  32. INSPECT DIFFERENTIAL PINION AND SIDE GEAR


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

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

  33. INSPECT DIFFERENTIAL CASE


    1. Check that no damaged is differential case.

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