REAR DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY


  1. PRECAUTION

    A0160DSE01
    Text in Illustration
    *A A Type
    *B B Type
    *a Hole

    The work procedures to be followed differ depending on the type of differential carrier right arm (A Type with a hole or B Type without a hole), so check whether the differential carrier right arm has a hole before disassembling.

    HINT
    Item A Type B Type
    Rear Differential Drive Pinion Bearing Spacer 41231-30050 41231-50010
    Rear Drive Pinion Front Tapered Roller Bearing 90366-34024 90366-34010
    Rear Drive Pinion Rear Tapered Roller Bearing 90366-45056 90366-45035

  2. REMOVE REAR DIFFERENTIAL BREATHER PLUG


    1. A01628I

      Remove the breather plug from the differential carrier cover.

  3. REMOVE REAR DIFFERENTIAL CARRIER COVER


    1. A0162YS

      Remove the 8 bolts from the differential carrier cover.

    2. A015ZZ6

      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.

  4. REMOVE REAR DIFFERENTIAL CARRIER STRAIGHT PIN


    1. Remove the 2 rear differential carrier straight pins.

  5. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A015ZPU

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

  6. SECURE REAR DIFFERENTIAL CARRIER


    1. A016396E01

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

  7. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. A0160J2E01

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

    2. Rotate the ring gear and measure the backlash.

      Maximum runout
      0.04 mm (0.00157 in.)

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

  8. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A016030E01

      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.

  9. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A0162BM

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

    2. Rotate the ring gear in both directions.

    3. Inspect the tooth contact pattern.

      A015ZRUE03
    4. A01639BE01

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

  10. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A0162J6

      Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0.15 mm (0.00591 in.) or less.

      If not, replace the rear differential case sub-assembly with a new one.

  11. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION


    1. A0160XK

      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 greater than the maximum, replace the drive pinion and ring gear.

  12. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01606GE01

      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.

      Differential Drive Pinion Preload (at Starting)
      A Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.25 to 1.65 N*m (12.75 to 16.83 kgf*cm, 11.06 to 14.60 in.*lbf)
      Used rear drive pinion tapered roller bearing 1.25 to 1.65 N*m (12.75 to 16.83 kgf*cm, 11.06 to 14.60 in.*lbf)
      B Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.44 to 2.01 N*m (14.68 to 20.50 kgf*cm, 12.74 to 17.79 in.*lbf)
      Used rear drive pinion tapered roller bearing 0.50 to 0.80 N*m (5.10 to 8.16 kgf*cm, 4.43 to 7.08 in.*lbf)

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

  13. INSPECT TOTAL PRELOAD


    1. A01606GE01

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

      Total Preload (at Starting)
      A Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 1.91 to 3.51 N*m (19.48 to 35.79 kgf*cm, 16.90 to 31.07 in.*lbf)
      Used rear drive pinion tapered roller bearing 1.74 to 2.96 N*m (17.74 to 30.18 kgf*cm, 15.40 to 26.20 in.*lbf)
      B Type
      Item Specified Condition
      New rear drive pinion tapered roller bearing 2.10 to 3.87 N*m (21.41 to 39.46 kgf*cm, 18.59 to 34.25 in.*lbf)
      Used rear drive pinion tapered roller bearing 0.99 to 2.11 N*m (10.10 to 21.52 kgf*cm, 8.76 to 18.67 in.*lbf)

  14. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01605JE01

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

      SST
      09308-00010

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


    1. A01625IE01

      Install SST to the differential carrier.

      SST
      09571-50010

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

    3. A015Z01E01

      Install a dial indicator to the rear differential carrier.

    4. Tighten the 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 shape of the differential carrier 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. A01629V

      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 the SST bolt.

      Note

      Do not remove SST.

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


    1. A0161HKE01

      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. A0162TQ

      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.

  17. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE LH


    1. A0162LOE01

      Tighten the 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. A01625IE02

      Remove SST.

  18. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE RH


    1. A0160X2E01

      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, check 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. Write down the result.

  19. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A0162RL

      Remove the rear differential case sub-assembly.

      Note

      Do not damage the case bearing.

  20. REMOVE REAR DRIVE PINION NUT


    1. A015YQEE01

      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. A01621CE01

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

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

  21. REMOVE REAR DRIVE PINION COMPANION FLANGE


    1. A0160XFE01

      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 the SST center bolt before use.

  22. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

    Tech Tips

    Perform this procedure only when the dust deflector is damaged.


    1. A0161RKE01

      Using SST and a press, remove the dust deflector.

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

  23. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A0160KLE01

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

      SST
      09308-00010

  24. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A0160SK

      Remove the drive pinion oil slinger.

  25. REMOVE DIFFERENTIAL DRIVE PINION


    1. A0161DWE01

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

      Note

      Do not drop the drive pinion.

  26. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A0162VNE01
      Text in Illustration
      *A A Type
      *B B Type

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

  27. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A016358

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

    2. A015Z7A

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

  28. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A015ZTUE01

      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. A01612S

      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 differential drive pinion plate washer.

  29. REMOVE DIFFERENTIAL RING GEAR


    1. A01601FE02

      Put matchmarks on the ring gear and differential case.

    2. Remove the 10 ring gear set bolts.

    3. A016230

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

      Note

      Do not damage the ring gear.

  30. 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. A0163DU

      Install the differential case to the differential carrier.

      Note

      Do not damage the case bearing.

    2. A015ZVOE01

      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. A0162JCE01

      Install SST to the differential carrier with the 2 bolts.

      SST
      09571-50010

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

    5. A0160YOE01

      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. A0162TQ

      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. A015ZG2E01

      Using a dial indicator, measure the differential case runout.

      Maximum runout
      0.04 mm (0.00157 in.)

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

    9. A0162TQ

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

    10. A0162NKE01

      Tighten the 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. A0160DFE01

      Remove the 2 bolts and SST.

    12. A0160X2E01

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

    13. A0162RL

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

      Note

      Do not damage the case bearing.

  31. REMOVE REAR DIFFERENTIAL CASE BEARING

    Tech Tips

    Perform this procedure only when replacing the rear differential case bearing or differential case sub-assembly.


    1. A0161RCE01

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

      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.

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

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

  32. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A0160GL

      Secure the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Place a dial indicator on the tip of the side gear tooth at a right angle. Hold the pinion gear in the differential case and check that the backlash is 0.15 mm (0.00591 in.) or less.

      If not, replace the rear differential case sub-assembly with a new one.