DIFFERENTIAL CARRIER ASSEMBLY (for LSD) DISASSEMBLY


  1. REMOVE REAR DIFFERENTIAL BREATHER PLUG


    1. A01GKEF

      Remove the breather plug from the differential carrier cover.

  2. REMOVE REAR DIFFERENTIAL CARRIER COVER


    1. A01GIRI

      Remove the 8 bolts from the differential carrier cover.

    2. A01GHL0

      Using a brass bar and a hammer, remove the differential carrier cover from the differential carrier.

      Note


      • Place the brass bar onto the corners of the carrier cover.

      • Do not damage the sealing surface of the differential carrier.

  3. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A01GID2

      Remove the bolt and oil deflector from the differential carrier cover.

  4. SECURE REAR DIFFERENTIAL CARRIER


    1. A01GJQU

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

  5. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. A01GHND

      Set the dial indicator perpendicular to the end of the ring gear face.

    2. Rotate the ring gear and measure the backlash.

      Maximum runout
      0.05 mm (0.00197 in.)

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

  6. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01GMG6

      While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

      Backlash
      0.08 to 0.13 mm (0.00315 to 0.00512 in.)

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

  7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01GKZ1

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

    2. Rotate the ring gear in both directions.

    3. Inspect the tooth contact pattern.

      A01GHRHE01
      Text in Illustration
      *a Proper Contact *b Heel Contact
      *c Face Contact *d Select an adjusting washer that will shift the drive pinion closer to the ring gear (*b, *c)
      *e Toe Contact *f Flank Contact
      g Select an adjusting washer that will shift the drive pinion away from to the ring gear (*e, *f) - -
    4. A01GJHTE04
      Text in Illustration
      *1 Rear Differential Drive Pinion Plate Washer

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

      Tech Tips


      • If the contact pattern is face contact or flank contact, tooth contact may be adjustable while keeping the backlash within the specified range.

      • If the thickness of the drive pinion washer has been changed, adjust the backlash and measure the total preload.

      Washer Thickness
      Thickness No. Thickness No. Thickness No.
      1.87 mm (0.0736 in.) 87 2.01 mm (0.0791 in.) 01 2.15 mm (0.0846 in.) 15
      1.88 mm (0.0740 in.) 88 2.02 mm (0.0795 in.) 02 2.16 mm (0.0850 in.) 16
      1.89 mm (0.0744 in.) 89 2.03 mm (0.0799 in.) 03 2.17 mm (0.0854 in.) 17
      1.90 mm (0.0748 in.) 90 2.04 mm (0.0803 in.) 04 2.18 mm (0.0858 in.) 18
      1.91 mm (0.0752 in.) 91 2.05 mm (0.0807 in.) 05 2.19 mm (0.0862 in.) 19
      1.92 mm (0.0756 in.) 92 2.06 mm (0.0811 in.) 06 2.20 mm (0.0866 in.) 20
      1.93 mm (0.0760 in.) 93 2.07 mm (0.0815 in.) 07 2.21 mm (0.0870 in.) 21
      1.94 mm (0.0764 in.) 94 2.08 mm (0.0819 in.) 08 2.22 mm (0.0874 in.) 22
      1.95 mm (0.0768 in.) 95 2.09 mm (0.0823 in.) 09 2.23 mm (0.0878 in.) 23
      1.96 mm (0.0772 in.) 96 2.10 mm (0.0827 in.) 10 2.24 mm (0.0882 in.) 24
      1.97 mm (0.0776 in.) 97 2.11 mm (0.0831 in.) 11 2.25 mm (0.0886 in.) 25
      1.98 mm (0.0780 in.) 98 2.12 mm (0.0835 in.) 12 2.26 mm (0.0890 in.) 26
      1.99 mm (0.0783 in.) 99 2.13 mm (0.0839 in.) 13 2.27 mm (0.0894 in.) 27
      2.00 mm (0.0787 in.) 00 2.14 mm (0.0843 in.) 14 2.28 mm (0.0898 in.) 28

  8. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION


    1. A01GK9V

      Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.394 in.) away from the end of the shaft.

      Maximum runout
      0.08 mm (0.00315 in.)

      If the runout is more than the maximum, replace the drive pinion and ring gear.

  9. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01GMSQE01

      Using SST and a torque wrench, measure the starting torque of the drive pinion. The backlash between the drive pinion and ring gear should allow enough movement of the drive pinion to allow this measurement to be performed. Make sure not to include the preload of the ring gear (differential case) in the measurement of the drive pinion preload.

      SST
      09229-55010
      Drive pinion preload (at starting)
      1.25 to 1.65 N*m (13 to 16 kgf*cm, 12 to 14 in.*lbf)

      If the preload is not within the specified range, adjust the rear differential drive pinion preload or repair as necessary.

  10. INSPECT TOTAL PRELOAD


    1. A01GMSQE01

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

      SST
      09229-55010
      Total preload (at starting)
      Item Specified Condition
      New bearing 1.91 to 3.51 N*m (20 to 35 kgf*cm, 17 to 31 in.*lbf)
      Reused bearing 1.74 to 2.96 N*m (18 to 30 kgf*cm, 16 to 26 in.*lbf)

  11. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01GMRUE01

      Using SST, remove the 2 rear differential side gear shaft oil seals.

      SST
      09308-00010

  12. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING (for RH Side)


    1. A01GN3NE03
      Text in Illustration
      *1 Disc

      Install SST to the differential carrier.

      SST
      09571-50010

    2. Tighten SST bolt (A) until SST disc lightly touches the differential side bearing outer race RH.

    3. A01GIZOE01

      Install a dial indicator to the rear differential carrier.

    4. Tighten SST bolt and alter the shape of the differential carrier to create a 0.1 mm (0.00394 in.) clearance between the differential side bearing outer race RH and side gear shaft snap ring.

      Note

      Observe the dial indicator to ensure that the clearance does not change more than 0.2 mm (0.00787 in.).

      Tech Tips


      • Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side gear shaft oil seal is tapped in.

      • Approximately 0.1 mm (0.00394 in.) clearance between the differential side bearing outer race RH and the side gear shaft snap ring is sufficient for the washer to move slightly.

    5. A01GLIM

      Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.

      Tech Tips

      For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result.

    6. Remove the dial indicator and loosen SST bolt.

      Note

      Do not remove SST.

  13. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING (for LH Side)


    1. A01GKG5E01

      Using SST and a hammer, create a clearance between the differential side bearing outer race LH on the back surface of the ring gear and side gear shaft snap ring.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      The clearance is not visible, but tapping SST with a hammer three or four times should be enough.

    2. A01GHQ7

      Using snap ring pliers, remove the side gear shaft snap ring on the back surface of the ring gear.

      Tech Tips

      For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result.

  14. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE LH


    1. A01GKPRE02
      Text in Illustration
      *a Turn

      Tighten SST bolt and push out the differential side bearing outer race LH on the back surface of the ring gear.

      SST
      09571-50010

      Note

      Do not drop the differential side bearing outer race LH.

    2. A01GNENE01

      Remove the 2 bolts and SST.

  15. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE RH


    1. A01GLEH

      Raise the ring gear of the differential case slightly to remove the ring gear tooth side differential side bearing outer race RH.

      Tech Tips

      For reassembly purposes, take note of the installation position of the differential side bearing outer race and the side gear shaft snap ring before removing the differential side bearing outer race.

  16. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01GJ6K

      Remove the rear differential case sub-assembly.

      Note

      Do not damage the case bearing.

  17. REMOVE REAR DRIVE PINION NUT


    1. A01GN7DE01

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

      SST
      09930-00010

      Note


      • Be sure to use SST with the tapered surface facing the shaft.

      • Do not grind the tip of SST with a grinder, etc.

      • Completely loosen the staked part of the nut when removing it.

      • Do not damage the threads of the drive pinion.

    2. A01GIZ4E01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the flange, remove the drive pinion nut.

      SST
      09229-55010
      09330-00021
      09950-30012   ( 09955-03040 )

  18. REMOVE REAR DRIVE PINION COMPANION FLANGE


    1. A01GI1RE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060 )

      Note

      Apply grease to the threads and tip of SST center bolt before use.

  19. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

    Tech Tips

    Perform this procedure only when the dust deflector is damaged.


    1. A01GJ9ZE01

      Using SST and a press, remove the dust deflector.

      SST
      09950-00020
      09950-60010   ( 09951-00440 )
      09950-70010   ( 09951-07100 )

  20. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01GNUKE01

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

      SST
      09308-00010

  21. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01GKPA

      Remove the drive pinion oil slinger.

  22. REMOVE DIFFERENTIAL DRIVE PINION


    1. A01GIJU

      Using a press, remove the drive pinion from the differential carrier.

      Note

      Do not drop the drive pinion.

  23. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01GJ9B

      Remove the rear differential drive pinion bearing spacer from the differential drive pinion.

  24. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01GMJO

      Remove the rear drive pinion front tapered roller bearing inner race from the differential carrier.

    2. A01GMWK

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

  25. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01GJ26E03

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

    2. A01GL27

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

    3. Remove the rear differential drive pinion plate washer.

  26. REMOVE DIFFERENTIAL RING GEAR


    1. A01GNAAE02
      Text in Illustration
      *a Matchmark

      Put matchmarks on the ring gear and differential case.

    2. Remove the 10 ring gear set bolts.

    3. A01GHX8

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

      Note

      Do not damage the ring gear.

  27. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY

    Tech Tips

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


    1. A01GJNF

      Install the differential case to the differential carrier.

      Note

      Do not damage the case bearing.

    2. A01GMIIE04
      Text in Illustration
      *a Groove

      Using SST and a hammer, install the differential side bearing outer race RH on the ring gear tooth side.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      Tap in the differential side bearing outer race RH until half of the side gear shaft snap ring groove of the differential carrier can be seen.

    3. A01GK2SE02
      Text in Illustration
      *1 Disc

      Install SST to the differential carrier with the 2 bolts.

      SST
      09571-50010

    4. Tighten SST bolt (A) until SST disc lightly touches the differential side bearing outer race RH.

    5. A01GJF1E01

      Using SST and a hammer, install the differential side bearing outer race LH on the ring gear back surface side.

      SST
      09608-32010
      09950-70010   ( 09951-07200 )

      Tech Tips

      Tap in the differential side bearing outer race LH until it touches the case bearing inner race roller.

    6. A01GHQ7

      Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.

    7. Place a dial indicator on the differential case flange surface at a right angle.

    8. A01GJ3U

      Using a dial indicator, measure the differential case runout.

      Maximum runout
      0.04 mm (0.00157 in.)

      If the runout is more than the maximum, replace the rear differential case with a new one.

    9. A01GHQ7

      Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.

    10. A01GLOPE02
      Text in Illustration
      *a Turn

      Tighten SST bolt to push out the ring gear back surface side differential side bearing outer race LH.

      Note

      Do not drop the differential side bearing outer race LH.

    11. A01GMC4

      Remove the 2 bolts and SST.

    12. A01GLEH

      Raise the ring gear side of the differential case slightly to remove the ring gear tooth side differential side bearing outer race RH.

    13. A01GJ6K

      Remove the differential case from the differential carrier as shown in the illustration.

      Note

      Do not damage the case bearing.

  28. REMOVE REAR DIFFERENTIAL CASE BEARING

    Tech Tips

    Perform this procedure only when replacing the case bearing or differential case.


    1. A01GK6XE02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the case bearing inner races LH and RH from the differential case.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00350, 09951-00480, 09952-06010 )

      Note


      • Do not deform the bearing cage if the bearing is to be reused.

      • Disengage SST claw from the dent of the differential case to the bearing inner race.

      • Apply grease to the threads and tip of SST center bolt before use.