REAR DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY


  1. SECURE DIFFERENTIAL CARRIER ASSEMBLY


    1. Secure the differential carrier assembly to the overhaul stand, etc.

  2. REMOVE REAR DIFFERENTIAL FILLER PLUG


    1. A01ELIW

      Using a hexagon wrench (17 mm), remove the rear differential filler plug (inspection plug) and gasket.

  3. REMOVE STUD BOLT


    1. A01EJ8UE10
      Text in Illustration
      *1 Hold
      *2 Turn
      *3 Upper Nut
      *4 Lower Nut

      Install 2 service nuts to the stud bolt.

      Recommended service nut
      Thread diameter
      8 mm (0.3150 in.)
      Thread pitch
      1.25 mm (0.0492 in.)

    2. Lock the upper nut using the lower nut.

    3. Turn the lower nut and remove the other 3 stud bolts in the same way.

      Tech Tips

      If the threads of the electro magnetic control coupling sub-assembly are damaged while removing the stud bolt, replace the electro magnetic control coupling sub-assembly with a new one.

  4. INSPECT RUNOUT OF ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY


    1. A01EKUHE01

      Install a dial indicator and magnetic base perpendicular to the inner side of the electro magnetic control coupling sub-assembly as shown in the illustration.

    2. Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the vertical runout.

      SST
      09564-32011
      Maximum runout
      0.065 mm (0.00255 in.)

      If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

    3. Install a dial indicator and magnetic base perpendicular to the electro magnetic control coupling sub-assembly as shown in the illustration.

    4. Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the lateral runout.

      SST
      09564-32011
      Maximum runout
      0.073 mm (0.00287 in.)

      If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

  5. REMOVE ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY


    1. A01EM9O

      Remove the 4 bolts. Using a plastic hammer, lightly tap the electro magnetic control coupling sub-assembly to remove it from the rear differential carrier assembly.

  6. REMOVE TRANSMISSION COUPLING CONICAL SPRING WASHER


    1. A01EK2BE01
      Text in Illustration
      *1 Transmission Coupling Conical Spring Washer

      Remove the transmission coupling conical spring washer from the rear differential carrier assembly.

  7. REMOVE TRANSMISSION COUPLING SPACER


    1. A01EKCHE01
      Text in Illustration
      *1 Transmission Coupling Spacer

      Remove the transmission coupling spacer from the rear differential carrier assembly.

  8. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR


    1. A01EJAXE01
      Text in Illustration
      *1 Tape
      *2 Matchmark

      Put matchmarks on the rear differential dust deflector and electro magnetic control coupling sub-assembly.

    2. Using a screwdriver, remove the rear differential dust deflector.

      Note


      • Pry the circumference of the rear differential dust deflector uniformly to prevent deformation.

      • Do not damage the end surface of the electro magnetic control coupling sub-assembly.

      Tech Tips


      • Tape the screwdriver tip before use.

      • If the end surface of the electro magnetic control coupling sub-assembly are damaged while removing the rear differential dust deflector, replace the electro magnetic control coupling sub-assembly with a new one.

  9. REMOVE CONNECTOR CLAMP BRACKET


    1. A01EJ9Q

      Disengage the claw and separate the connector.

    2. Remove the bolt and connector clamp bracket.

      Note

      Do not damage the electro magnetic control coupling wire harness.

  10. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a ring gear tooth tip.

    2. A01EIT3E02

      Using SST, hold the drive pinion in place.

      SST
      09556-16011

    3. Using SST, rotate the rear differential case forward and backward, and measure the backlash.

      SST
      09564-32011
      Backlash
      0.10 to 0.22 mm (0.00394 to 0.00866 in.)

      Note

      Measure at 3 or more areas on the circumference of the ring gear.

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

  11. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01EJUUE01

      Using SST and a torque wrench, inspect the differential drive pinion preload (starting torque) of the backlash between the differential drive pinion and differential ring gear.

      SST
      09556-16011
      Standard drive pinion preload
      0.4 to 0.7 N*m (4 to 7 kgf*cm, 3 to 6 in.*lbf)

      Note

      For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

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

  12. INSPECT TOTAL PRELOAD


    1. A01EJUUE01

      Using SST and a torque wrench, inspect the total preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.

      SST
      09556-16011
      Standard total preload
      Standard drive pinion preload plus 0.3 to 0.5 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)

      Note

      For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

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

  13. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01EKD0E01

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

      SST
      09308-00010

  14. REMOVE REAR DRIVE PINION NUT


    1. A01EMFGE01

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

      SST
      09930-00010

      Note


      • Use SST with the tapered part facing against the shaft.

      • Do not modify the SST tip with a grinder or equivalent.

      • Fully unstake the rear drive pinion nut.

    2. A01EMAAE03

      Using SST, hold the differential drive pinion in place and remove the rear drive pinion nut from the differential drive pinion.

      SST
      09556-16011
      09564-16020

  15. REMOVE DIAPHRAGM OIL SEAL


    1. A01ELKKE02

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

      SST
      09308-10010

  16. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01EIR8E02

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

      SST
      09556-40010

  17. REMOVE DIFFERENTIAL PRESSURE CONTROL HOSE


    1. A01EMEU

      Remove the 2 differential pressure control hose clips and rear differential pressure control hose.

  18. REMOVE DIFFERENTIAL PRESSURE CONTROL HOSE ELBOW


    1. A01EKK1E02
      Text in Illustration
      *1 Matchmark

      Put matchmarks on the 2 differential pressure control hose elbows and rear differential carrier assembly.

    2. Using a screwdriver, remove the 2 differential pressure control hose elbows.

      Tech Tips

      Tape the screwdriver tip before use.

  19. REMOVE DIFFERENTIAL SIDE BEARING RETAINER


    1. A01EJAK

      Remove the 10 bolts from the rear differential carrier assembly.

    2. A01ELHC

      Using a brass bar and a hammer, lightly tap out the differential side bearing retainer from the rear differential carrier assembly.

      Note

      Set the brass bar on the ribbed part of the differential side bearing retainer.

  20. REMOVE REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG


    1. A01EJOR

      Using a screwdriver, remove the rear differential carrier cover breather plug from the differential side bearing retainer.

      Tech Tips

      Tape the screwdriver tip before use.

  21. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A01EKNH

      Remove the 2 bolts and rear differential breather plug oil deflector.

  22. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01EJ0F

      Remove the rear differential case sub-assembly from the rear differential carrier.

  23. REMOVE DIFFERENTIAL DRIVE PINION


    1. A01EJXS

      Remove the differential drive pinion from the rear differential carrier.

  24. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01EK6W

      Remove the rear differential drive pinion oil slinger from the differential drive pinion.

  25. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01ELFI

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

  26. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01EJF1E01

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

      SST
      09950-00020

      Note

      If the rear differential drive pinion or differential ring gear is damaged, replace them both.

    2. Remove the rear differential drive pinion plate washer.

  27. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01EM1ME02

      Using SST, remove the rear drive pinion front tapered roller bearing (outer race) from the rear differential carrier.

      SST
      09612-65014   ( 09612-01020, 09612-01050 )

  28. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01ELCQ

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

      Note

      Set the brass bar on the notch.

  29. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. A01EMJJE01

      Using SST and a press, remove the rear differential case bearing (RH side outer race) and rear differential side gear shaft plate washer from the rear differential carrier.

      SST
      09950-60010   ( 09951-00580 )
      09950-70010   ( 09951-07100 )

  30. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. A01ELBJE01

      Using SST and a press, remove the rear differential case bearing (LH side outer race) and rear differential side gear shaft plate washer from the differential side bearing retainer.

      SST
      09950-60010   ( 09951-00580 )
      09950-70010   ( 09951-07100 )
      09223-15020

  31. REMOVE STRAIGHT PIN


    1. Remove the 4 straight pins from the rear differential carrier.

      A01ELP3

  32. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. A01EIRZE03

      Using SST, remove the rear differential case bearing (RH side inner race) from the rear differential case sub-assembly.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00370 )

      Note

      Before using the SST center bolt (09953-04020), apply hypoid gear oil to its threads and tip.

      Tech Tips

      If the race remains on the rear differential case sub-assembly, repeat the step above to remove the race.

  33. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. A01EMCHE03

      Using SST, remove the rear differential case bearing (LH side inner race) from the rear differential case.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00370 )

      Note

      Before using the SST center bolt (09953-04020), apply hypoid gear oil to its threads and tip.

      Tech Tips

      If the race remains on the rear differential case sub-assembly, repeat the step above to remove the race.

  34. REMOVE DIFFERENTIAL RING GEAR


    1. A01EMAUE02
      Text in Illustration
      *1 Matchmark

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

    2. Remove the 10 ring gear set bolts.

    3. Using a plastic-faced hammer, lightly tap the outer circumference of the differential ring gear to remove it from the rear differential case sub-assembly.

  35. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01EK78

      Using a pin punch (3 mm) and a hammer, remove the rear differential pinion shaft pin.

  36. REMOVE DIFFERENTIAL PINION AND SIDE GEAR


    1. A01EJ6EE02
      Text in Illustration
      *1 Differential Pinion Gear
      *2 Rear Differential Pinion Thrust Washer
      *3 Rear Differential Pinion Shaft
      *4 Differential Side Gear
      *5 Rear No. 1 Differential Side Gear Thrust Washer

      Remove the following components from the rear differential case:

  37. INSPECT DIFFERENTIAL PINION AND SIDE GEAR


    1. Check the differential pinion gears and differential side gears for wear.

  38. INSPECT REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. Check the differential case for cracks or damage.