REAR DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY


  1. REMOVE REAR DIFFERENTIAL CARRIER COVER


    1. A017CVA

      Remove the 8 bolts from the rear differential carrier cover.

    2. Using a brass bar and a hammer, separate the rear differential carrier cover from rear differential carrier assembly.

  2. REMOVE REAR DIFFERENTIAL BREATHER PLUG


    1. A017EX8

      Remove the rear differential breather plug from the rear differential carrier cover.

  3. SECURE REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. A017C2W

      Set the differential carrier to an overhaul stand, etc. as shown in the illustration.

  4. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. A017CDL

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

      Maximum runout
      0.07 mm (0.0028 in.)

      If the runout exceeds the specified maximum value, remove the ring gear and check the runout of the differential case.

  5. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A017CU0

      Using a dial indicator, check the backlash of the differential 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.

  6. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A017F6E

      Coat 3 or 4 teeth at 3 different positions on the differential ring gear with Prussian blue.

    2. Hold the rear drive pinion companion flange sub-assembly firmly and rotate the differential ring gear in both directions.

    3. Inspect the tooth contact pattern.

      A017CM8E05

      If the teeth are not contacting properly, use the following table to select a proper washer for correction.

      Washer thickness
      Thickness mm (in.) Thickness mm (in.) Thickness mm (in.)
      2.26 to 2.28 (0.0890 to 0.0898) 2.41 to 2.43 (0.0949 to 0.0957) 2.56 to 2.58 (0.1008 to 0.1016)
      2.29 to 2.31 (0.0902 to 0.0909) 2.44 to 2.46 (0.0961 to 0.0969) 2.59 to 2.61 (0.1020 to 0.1028)
      2.32 to 2.34 (0.0913 to 0.0921) 2.47 to 2.49 (0.0972 to 0.0980) 2.62 to 2.64 (0.1031 to 0.1039)
      2.35 to 2.37 (0.0925 to 0.0933) 2.50 to 2.52 (0.0984 to 0.0992) 2.65 to 2.67 (0.1043 to 0.1051)
      2.38 to 2.40 (0.0937 to 0.0945) 2.53 to 2.55 (0.0996 to 0.1004) 2.68 to 2.70 (0.1055 to 0.1063)

  7. INSPECT DIFFERENTIAL PINION AND SIDE GEAR BACKLASH


    1. A017ELF

      Using a dial indicator, check the backlash of the differential side gear while holding one of the pinion gears toward the differential case assembly.

      Backlash
      0.05 to 0.20 mm (0.0020 to 0.0079 in.)

      If the backlash is not within the specification, install the 2 differential side gear thrust washers of different thicknesses Click here.

      Tech Tips

      Measure the backlash of the differential side gear with the rear differential pinion shaft installed.

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


    1. A017F2PE02

      Using a dial indicator, measure the runout of the rear drive pinion companion flange sub-assembly vertically and horizontally.

      (A)
      30 mm (1.18 in.)
      Maximum runout
      0.10 mm (0.0039 in.)

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

  9. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A017G9T

      Using a torque wrench, measure the preload of the differential drive pinion.

      Drive pinion preload (Initial)
      Preload
      0.6 to 0.9 N*m (6.1 to 9.2 kgf*cm, 5.3 to 8.0 in.*lbf)

      If the preload is not within the specified range, adjust the total preload or repair as necessary.

  10. INSPECT TOTAL PRELOAD


    1. A017G9T

      Using a torque wrench, measure the total preload.

      Total preload (Initial)
      Drive pinion preload plus 0.3 to 0.5 N*m (3.1 to 5.1 kgf*cm, 2.7 to 4.4 in.*lbf)

      If the preload is not within the specified range, adjust the total preload or repair as necessary.

  11. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A017FM7E01

      Using SST, remove the 2 rear differential side gear shaft oil seals from the rear differential carrier sub-assembly.

      SST
      09308-00010

  12. REMOVE REAR DRIVE PINION NUT


    1. A017F32E01

      Using SST and a hammer, unstake the staked part of the rear drive pinion nut.

      SST
      09930-00010
    2. A017DT6E01

      Using SST to hold the rear drive pinion companion flange sub-assembly, remove the rear drive pinion nut.

      SST
      09330-00021

  13. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A017G5UE01

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

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020 )

  14. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR


    1. A017BI3E01

      Using SST and a press, remove the rear differential dust deflector.

      SST
      09950-60010   ( 09951-00360 )
      09950-70010   ( 09951-07150 )
      09950-00020

  15. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A017GBHE01

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

      SST
      09308-10010

  16. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  17. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A017BOBE01

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

      SST
      09556-22010

  18. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

  19. REMOVE REAR DIFFERENTIAL CASE


    1. A017ELWE01

      Put matchmarks on the rear differential bearing cap and rear differential carrier sub-assembly.

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

    3. A017B1XE01

      Using SST and a hammer, remove the 2 rear differential side gear shaft plate washers.

      SST
      09504-22011

      Tech Tips

      Measure the thicknesses of the rear differential side gear shaft plate washers and note them down.

    4. A017FVU

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

      Tech Tips

      Tag the 2 rear differential case bearing outer races to show the location for reassembly.

  20. REMOVE DIFFERENTIAL DRIVE PINION


    1. Remove the differential drive pinion.

  21. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A017DPHE01

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

      SST
      09950-00020

      Tech Tips

      If either the differential drive pinion or differential ring gear is damaged, replace both as a set.

    2. Remove the rear differential drive pinion plate washer.

  22. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A017F9AE01

      Using a brass bar and a hammer, remove the rear drive pinion front tapered roller bearing (outer race) from the rear differential carrier sub-assembly.

  23. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A017D93E01

      Using a brass bar and a hammer, remove the rear drive pinion rear tapered roller bearing (outer race) from the rear differential carrier sub-assembly.

  24. REMOVE DIFFERENTIAL RING GEAR


    1. A017CMZE01

      Put matchmarks on the differential ring gear and rear differential case.

    2. Using a screwdriver and a hammer, unstake the 4 rear differential ring gear set bolt lock plates.

    3. Remove the 8 bolts and 4 rear differential ring gear set bolt lock plates.

  25. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE

    Tech Tips

    Perform this procedure only if the runout of the differential ring gear exceeds the specified maximum value.


    1. A017DP2

      Install the rear differential case to the rear differential carrier sub-assembly.

    2. Install the right and left rear differential bearing caps with the 4 bolts.

      Torque:
      79 N*m  { 800 kgf*cm, 58 ft.*lbf }

    3. Using a dial indicator, measure the differential case runout.

      Maximum runout
      0.07 mm (0.0028 in.)

      If the runout is greater than the maximum value, replace the differential case assembly with a new one.

    4. Remove the rear differential case.

  26. REMOVE REAR DIFFERENTIAL CASE BEARING (for LH Side)


    1. A017DZNE01

      Using SST, remove the rear differential case bearing from the rear differential case.

      SST
      09950-40011   ( 09951-00240, 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00360 )

  27. REMOVE REAR DIFFERENTIAL CASE BEARING (for RH Side)


    1. A017D9AE01

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

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

  28. REMOVE REAR DIFFERENTIAL PINION SHAFT


    1. A017ELO

      Using a pin punch (5 mm) and a hammer, remove the rear differential pinion shaft straight pin.

    2. A017FD3E01

      Remove the rear differential pinion shaft. (A)

    3. Remove the 2 differential pinion gears. (B)

    4. Remove the 2 rear differential pinion thrust washers. (C)

    5. Remove the 2 differential side gears. (D)

    6. Remove the 2 No. 1 rear differential side gear thrust washers. (E)

  29. INSPECT DIFFERENTIAL PINION AND SIDE GEAR


    1. Check that there is no damage to the differential pinion gears and side gears. If the differential pinion gears and/or side gears are damaged, replace them with new ones.

  30. INSPECT REAR DIFFERENTIAL CASE


    1. Check that there is no damage to the differential case. If the differential case is damaged, replace it.