DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY


  1. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. A003C8X

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

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


    1. A003I0IE11

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

      Maximum runout
      0.10 mm (0.0039 in.)

      If the runout is greater than the maximum value, replace the companion flange sub-assembly.

  3. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. A003EW0

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

    2. Rotate the ring gear and measure the runout.

      Maximum runout
      0.07 mm (0.0028 in.)

      Tech Tips

      Measure at a radial position 92 mm (3.62 in.) from the center of the ring gear.

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

  4. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A003HNR

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

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

      Backlash
      0.13 to 0.18 mm (0.0051 to 0.0071 in.)

      Tech Tips

      Inspect the backlash at 3 or more locations on the ring gear.

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

  5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A003DBL

      Using a socket wrench (30 mm) and torque wrench, measure the preload using the backlash of the drive pinion and ring gear.

      Preload (at starting)
      0.52 to 0.81 N*m (6 to 8 kgf*cm, 5 to 7 in.*lbf)

  6. INSPECT TOTAL PRELOAD


    1. A003DBL

      Using a socket wrench (30 mm) and torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

      Total preload (at starting)
      Drive pinion preload plus 0.39 to 0.59 N*m (4.0 to 6.0 kgf*cm, 3.5 to 5.2 in.*lbf)

  7. REMOVE REAR DRIVE PINION NUT


    1. A003DRCE01

      Using SST and a hammer, release 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. A003CE9E01

      Using SST, hold the flange.

      SST
      09330-00021

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

  8. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A003FM6E01

      Using SST, remove the companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03040 )

      Note

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

  9. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

    Tech Tips

    Perform this procedure only when the dust deflector is damaged.


    1. A003G65E01

      Using SST and a press, remove the dust deflector.

      SST
      09950-60010   ( 09951-00380 )
      09950-70010   ( 09951-07150 )
      09950-00020

  10. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A003AGJE01

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

      SST
      09308-10010

      Note

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

  11. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  12. REMOVE REAR DRIVE PINION FRONT BEARING


    1. A003GOCE01

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

      SST
      09556-22010

      Note

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

  13. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A003D0B

      Remove the 2 bolts and 2 bearing adjusting nut locks.

  14. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A003BMWE01

      Put matchmarks on either set of the bearing cap and the differential carrier.

    2. Remove the 4 bolts and 2 bearing caps.

      Note

      Do not swap the bearing caps on the carrier as they are manufactured as a set.

    3. Remove the 2 rear differential bearing adjusting nuts.

    4. A003C39

      Remove the differential case assembly and case bearing outer races LH and RH from the differential carrier.

    5. A003FZS

      Put identification marks on the case bearing outer races and bearing adjusting nuts to distinguish between the RH side and LH side.

  15. REMOVE DIFFERENTIAL DRIVE PINION


    1. A003GR7

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

  16. REMOVE REAR DRIVE PINION REAR BEARING


    1. A003ASWE01

      Using SST and a press, remove the inner race of the rear drive pinion rear tapered roller bearing 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. Remove the drive pinion plate washer from the drive pinion.

  17. REMOVE REAR DRIVE PINION FRONT BEARING


    1. A003FD9

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

  18. REMOVE DIFFERENTIAL OIL STORAGE RING


    1. A003EEV

      Using a brass bar and a hammer, remove the oil storage ring from the differential carrier.

  19. REMOVE REAR DRIVE PINION REAR BEARING


    1. A003G33

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

  20. REMOVE DIFFERENTIAL RING GEAR


    1. A003HHJE01

      Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Put matchmarks on the ring gear and differential case.

    3. Using a screwdriver and a hammer, release the 5 lock plates.

    4. A003IDVE01

      Remove the 10 ring gear set bolts and 5 lock plates.

    5. A003CMG

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

      Tech Tips

      Place a cloth under the toothed surface of the ring gear to prevent damage.

  21. INSPECT RUNOUT OF DIFFERENTIAL CASE ASSEMBLY

    Tech Tips

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


    1. Install the case bearing outer races LH and RH to the case bearing inner races LH and RH respectively.

      Note

      Be sure to install the bearing outer races in each correct position.

    2. Install the differential case to the differential carrier.

    3. Align the matchmarks on the bearing cap and differential carrier.

    4. Install the right and left bearing caps with the 4 bolts.

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }
    5. A003F0L

      Using a dial indicator, measure the differential case runout.

      Maximum case runout
      0.04 mm (0.0016 in.)

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

    6. Remove the 4 bolts, right and left bearing caps and differential case.

  22. REMOVE REAR DIFFERENTIAL CASE BEARING

    Tech Tips

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


    1. A003DKRE01

      Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. 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   ( 09951-00360 )

      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.

  23. DISASSEMBLE DIFFERENTIAL CASE (2 Pinion Type)


    1. A003HRZ

      Using a pin punch (5 mm) and a hammer, remove the straight pin.

    2. A003ACZE02

      Remove the following parts from the differential case.

      (1) Rear differential pinion shaft
      (2) Rear differential pinion
      (3) Rear differential pinion thrust washer
      (4) Rear differential side gear
      (5) Rear No. 1 differential side gear thrust washer

  24. DISASSEMBLE DIFFERENTIAL CASE (4 Pinion Type)


    1. A003AJ4E04

      Place matchmarks on the LH and RH cases.

    2. Remove the 8 bolts.

      Tech Tips

      Loosen the bolts gradually, always skipping to a diagonally opposite bolt.

    3. A003BSU

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

    4. A003GLXE03

      Remove the following parts from the differential case.

      (1) Rear differential spider
      (2) Rear differential pinion
      (3) Rear differential pinion thrust washer
      (4) Rear differential side gear
      (5) Rear No. 1 differential side gear thrust washer

  25. INSPECT DIFFERENTIAL PINION AND SIDE GEAR


    1. Check that there is no damage to the differential pinion gear and side gear.

      If the differential pinion gear and/or side gear are damaged, replace them with new ones.

  26. INSPECT DIFFERENTIAL CASE


    1. Check that there is no damage to the differential case. If the differential case is damaged, replace it.