REAR DIFFERENTIAL CARRIER ASSEMBLY (w/o Differential Lock) DISASSEMBLY


  1. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY IN PLACE

    A01DR8O

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

    A01DOC6E20
    Text in Illustration
    *a Vertical Runout
    *b Lateral Runout

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

      Distance from center to runout measurement point
      30 mm (1.18 in.)
      Maximum Runout
      Item Specified Condition
      Vertical runout 0.10 mm (0.00394 in.)
      Lateral runout 0.10 mm (0.00394 in.)

      • If the runout is more than the maximum, replace the companion flange.

  3. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

    A01DQRY

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

      Maximum runout
      0.07 mm (0.00276 in.)

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

  4. INSPECT DIFFERENTIAL RING GEAR BACKLASH

    A01DLZ9

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

      Standard backlash
      0.10 to 0.20 mm (0.00394 to 0.00787 in.)

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

        Tech Tips

        Perform the measurement at 3 or more positions around the circumference of the ring gear.

  5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

    A01DM7QE01

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

      Standard preload (at starting)
      0.88 to 1.98 N*m (9.0 to 20.2 kgf*cm, 7.8 to 17.5 in.*lbf)

      If necessary, disassemble and inspect the differential.

  6. INSPECT TOTAL PRELOAD

    A01DM7QE01

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

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

      Standard total preload (at starting)
      Drive pinion preload plus 0.20 to 0.40 N*m (2.04 to 4.07 kgf*cm, 1.77 to 3.54 in.*lbf)

      If necessary, disassemble and inspect the differential.

  7. REMOVE REAR DRIVE PINION NUT

    A01DR3SE01

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

      SST
      09930-00010
    2. A01DQDUE03

      Use SST to hold the companion flange.

      SST
      09330-00021

    3. Using a 30 mm socket wrench, remove the rear drive pinion nut.

  8. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    A01DO5XE01

    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.

  9. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

    A01DOODE02

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

      SST
      09308-10010

  10. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  11. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (INNER)

    A01DUQGE01

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

      SST
      09556-22010

  12. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (OUTER)

  13. REMOVE DIFFERENTIAL CASE ASSEMBLY

    A01DNS1E02

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

      Text in Illustration
      *a Matchmark

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

    3. A01DOXH

      Using a screwdriver and hammer, remove the 2 plate washers.

      Tech Tips

      Measure the plate washer thickness and note it down.

    4. A01DMZC

      Remove the rear differential case assembly from the differential carrier.

      Tech Tips

      Tag the 2 case bearing outer races so that they can be reinstalled in the correct locations.

  14. REMOVE DIFFERENTIAL DRIVE PINION


    1. A01DPQ5

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

  15. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    A01DUAZE01

    1. Using SST and a press, press out the roller bearing (inner) from the drive pinion.

      SST
      09950-00020

      Note

      Do not drop the drive pinion.

      Tech Tips

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

  16. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    A01DRW0E01

    1. Using SST, remove the roller bearing (outer) from the carrier.

      SST
      09308-00010

    2. Using a brass bar and hammer, tap out the oil storage ring from the carrier.

      Tech Tips

      If the bearing is damaged during removal, replace it.

  17. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    A01DQZ3E01

    1. Using SST, tap out the rear tapered roller bearing (outer) from the carrier.

      SST
      09308-00010

      Tech Tips

      If the bearing is damaged during removal, replace it.

  18. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

  19. REMOVE DIFFERENTIAL RING GEAR

    A01DMHSE02

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

      Text in Illustration
      *a Matchmark

    2. Remove the 12 ring gear set bolts.

    3. A01DSLLE02

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

  20. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT

    A01DUDO

    1. Install the rear differential case bearing to the differential case.

    2. Install the differential case to the differential carrier.

    3. Install the 2 bearing caps to the differential carrier with the 4 bolts.

      Torque:
      103 N*m  { 1049 kgf*cm, 76 ft.*lbf }

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

      Maximum runout
      0.07 mm (0.00276 in.)

    5. Remove the differential case.

    6. Remove the rear differential case bearing.

  21. REMOVE REAR DIFFERENTIAL CASE BEARING

    A01DQWCE02

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

      SST
      09950-40011   ( 09953-04020, 09951-04010, 09952-04010, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00500, 09951-00650, 09952-06010 )

      Note

      Do not remove a case bearing unless replacing the differential case.

  22. DISASSEMBLE DIFFERENTIAL CASE

    A01DTHAE02

    1. Place matchmarks on the LH and RH cases.

      Text in Illustration
      *a Matchmark

    2. Remove the 8 bolts.

      Note

      Loosen the bolts, diagonally opposite of each other, in pairs.

    3. A01DMP3

      Using a plastic-faced hammer, separate the LH and RH cases.

    4. A01DLVDE05
      Text in Illustration
      *1 Side Gear
      *2 Side Gear Thrust Washer
      *3 Spider
      *4 Pinion Gear
      *5 Pinion Gear Thrust Washer

      Remove the parts shown in the illustration from the differential case.