DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY


  1. REMOVE REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG


    1. A01H175

      Remove the breather plug from the differential carrier cover.

  2. REMOVE REAR DIFFERENTIAL CARRIER COVER


    1. A01H1X5

      Remove the 8 bolts from the differential carrier cover.

    2. A01GXE2

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

      Note


      • Set the brass bar on the ribbed part of the differential carrier cover.

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

  3. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A01GWLF

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

  4. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY TO OVERHAUL STAND


    1. A01GXYRE01

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

      Tech Tips

      Install the differential carrier with the back surface of the ring gear facing the overhaul stand as shown in the illustration.

  5. INSPECT DIFFERENTIAL RING GEAR RUNOUT


    1. A01GZXOE01

      Place a dial indicator so that it is perpendicular to the back surface of the ring gear.

    2. Rotate the ring gear and measure the ring gear runout.

      Maximum runout
      0.05 mm (0.00197 in.)

      Tech Tips

      For reassembly purposes, record the result before disassembly.

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

  6. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01H0T3E01

      Place a Place a dial indicator so that it is perpendicular to the top of the ring gear on the tooth side.

    2. Fix the companion flange in place, and measure the ring gear backlash.

      Standard backlash
      0.08 to 0.13 mm (0.00315 to 0.00511 in.)

      Tech Tips


      • Measure the ring gear at 3 or more different places.

      • For reassembly purposes, record the result before disassembly.

  7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01GZ3G

      Uniformly apply a light coat of Prussian blue on both sides of 4 teeth on the differential ring gear.

    2. A01H05B

      Rotate the companion flange several times in the forward and backward rotation directions.

    3. Inspect the tooth contact pattern.

      A01GZI7E02

      Tech Tips


      • The patterns indicated by the Prussian blue are the tooth contact locations.

      • For reassembly purposes, record the result before disassembly.

      Note

      Check the tooth contact pattern at 4 positions around the circumference of the ring gear.

  8. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01H1JA

      Place a dial indicator on the tip of the side gear tooth at a right angle.

    2. Hold the side gear in the differential case and check that the backlash is 0 mm (0 in.). If not, replace the rear differential case with a new one.

  9. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION


    1. A01GYTIE01

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

      Maximum runout
      0.08 mm (0.00315 in.)

      Tech Tips

      For reassembly purposes, record the result before disassembly.

  10. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01GZ41E01

      Using SST, remove the 2 oil seals.

      SST
      09308-00010

  11. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING


    1. A01GZOLE04
      Text in Illustration
      *1 Disc

      Install the 2 bolts and SST to the differential carrier.

      SST
      09571-50010

    2. Tighten SST bolt until SST disc lightly touches the case bearing outer race.

    3. A01GXISE01

      Install a dial indicator to the rear differential carrier.

    4. Tighten SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.00394 in.) clearance between the case bearing outer race 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

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

    5. A01GXXH

      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 differential side gear shaft snap ring, and record the result.

      • Place distinguishing marks on the left and right side differential side gear shaft snap rings to distinguish them (back surface side, tooth side). Then store them separately.

    6. Remove the dial indicator from the differential carrier.

    7. A01GXRRE02
      Text in Illustration
      *1 Disc
      *a Turn

      Loosen SST bolt until SST disc separates from the tooth side of the differential case bearing outer race.

      Tech Tips

      Do not remove SST.

  12. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING


    1. A01H28XE02

      Using SST and a hammer, create a clearance between the case bearing outer race 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 3 or 4 times should be enough.

    2. A01GWLB

      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 differential side gear shaft snap ring, and record the result.

      • Place distinguishing marks on the left and right side differential side gear shaft snap rings to distinguish them (back surface side, tooth side). Then store them separately.

  13. REMOVE REAR DIFFERENTIAL CASE BEARING OUTER RACE


    1. A01GY8YE03
      Text in Illustration
      *a Turn

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

      SST
      09571-50010

      Note

      Do not drop the case bearing outer race.

      Tech Tips


      • For reassembly purposes, mark the installation positions of the differential case bearing outer race and differential side gear shaft snap ring.

      • Place distinguishing marks on the left and right side differential case bearing outer races to distinguish them (back surface side, tooth side). Then store them separately.

    2. A01GZOLE05
      Text in Illustration
      *1 Disc

      Remove the 2 bolts and SST from the differential carrier.

  14. REMOVE REAR DIFFERENTIAL CASE BEARING OUTER RACE


    1. A01GYUNE01

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

      Note

      Do not drop the case bearing outer race.

      Tech Tips


      • For reassembly purposes, mark the installation positions of the differential case bearing outer race and differential side gear shaft snap ring.

      • Place distinguishing marks on the left and right side differential case bearing outer races to distinguish them (back surface side, tooth side). Then store them separately.

  15. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01GXTA

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

      Note

      Do not damage the case bearing and ring gear.

  16. REMOVE REAR DRIVE PINION NUT


    1. A01GYI5E02

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

      SST
      09930-00010

      Note


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

      • Completely unstake the drive pinion nut to prevent damaging the threads of the drive pinion.

    2. A01H1N6E03
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, fix the companion flange in place.

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

    3. While supporting the overhaul attachment, using SST, remove the rear drive pinion nut.

      SST
      09229-55010

  17. REMOVE REAR DRIVE PINION COMPANION FLANGE REAR SUB-ASSEMBLY


    1. A01H0VJE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the companion flange from the differential carrier.

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

      Tech Tips

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

  18. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

    Tech Tips

    Perform this procedure only when the dust deflector is damaged.


    1. A01GY0UE02

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

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

      Tech Tips

      Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the dust deflector.

      Note

      Do not drop the companion flange.

  19. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01H08LE02

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

      SST
      09308-00010

  20. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01GY0N

      Using a magnet hand, remove the oil slinger from the differential carrier.

  21. REMOVE DIFFERENTIAL DRIVE PINION


    1. A01H0C2

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

      Note

      Do not drop the drive pinion.

  22. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01H1L3

      Remove drive pinion bearing spacer from the drive pinion.

  23. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING INNER RACE


    1. A01GZ36

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

  24. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING OUTER RACE


    1. A01H157

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

      Note

      Make sure to preform this procedure with the brass bar placed on the rear drive pinion front tapered roller bearing outer race . Do not damage the differential carrier.

  25. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING INNER RACE


    1. A01GX8BE01

      Using SST and a press, press out the rear drive pinion rear tapered roller bearing inner race from the drive pinion.

      SST
      09950-00020

      Tech Tips

      Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the rear tapered roller bearing inner race.

      Note

      Do not drop the drive pinion.

  26. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING OUTER RACE


    1. A01GZAE

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

      Note

      Make sure to perform this procedure with the brass bar placed on the differential drive pinion washer. Do not damage the differential carrier.

      Tech Tips

      For reassembly purposes, measure the thickness of the differential drive pinion washer, and record the result.

  27. REMOVE DIFFERENTIAL RING GEAR


    1. Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A01GYJME01
      Text in Illustration
      *a Matchmark

      Put matchmarks on the ring gear and differential case.

    3. Remove the 10 ring gear set bolts.

    4. Remove the differential case from the vise.

    5. A01GXTR

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

      Tech Tips

      Place a cloth on the tooth side of the ring gear to prevent damage.

  28. INSPECT RUNOUT OF REAR DIFFERENTIAL CARRIER ASSEMBLY

    Tech Tips

    Only perform this procedure if the runout exceeded the maximum value during the inspection of the ring gear runout inspection.


    1. A01GZWW

      Install the differential case to the differential carrier.

      Note

      Do not damage the case bearing.

    2. A01H2AVE01
      Text in Illustration
      *a Groove

      Using SST and a hammer, tap in the case bearing outer race on the ring gear tooth side.

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

      Tech Tips

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

    3. A01GZ1GE06
      Text in Illustration
      *1 Disc

      Install SST to the differential carrier with the 2 bolts.

      SST
      09571-50010

    4. Tighten SST bolt until SST disc lightly touches the case bearing outer race.

      Tech Tips

      Tighten SST bolt to apply preload to the differential case bearing.

    5. A01GX78E02

      Using SST and a hammer, tap in the case bearing outer race on the ring gear back surface side.

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

      Tech Tips

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

    6. A01GWLB

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

    7. A01GX1BE02

      Place a dial indicator so that it is perpendicular to the differential case flange face.

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

      Maximum runout
      0.05 mm (0.00197 in.)

      Note

      Do not remove SST.

    9. A01GWLB

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

    10. A01GZKXE03
      Text in Illustration
      *a Turn

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

      SST
      09571-50010

      Note

      Do not drop the case bearing outer race.

    11. A01GWD0E01

      Remove the 2 bolts and SST from the differential carrier.

    12. A01GZ2R

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

    13. A01GX6I

      Remove the differential case from the differential carrier.

      Note

      Do not damage the case bearing.

  29. REMOVE REAR DIFFERENTIAL CASE BEARING INNER RACE

    Tech Tips

    Do not remove the rear differential case bearing unless replacing the differential case or differential case bearing.


    1. Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A01GZO2E06
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the case bearing inner race 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.

      Tech Tips


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

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

  30. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A01H1H7E01

      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 mm (0 in.).

      If the backlash is not as specified, replace the rear differential case with a new one.