DIFFERENTIAL CARRIER ASSEMBLY(for LSD) DISASSEMBLY

PROCEDURE


  1. REMOVE REAR DIFFERENTIAL BREATHER PLUG


    1. A001C8M

      Remove the breather plug from the differential carrier cover.

  2. REMOVE REAR DIFFERENTIAL CARRIER COVER


    1. A001DBT

      Remove the 8 bolts from the differential carrier cover.

    2. A001BKU

      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.

  3. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A001CVX

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

  4. SECURE REAR DIFFERENTIAL CARRIER


    1. A001BI2

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

  5. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

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  6. INSPECT DIFFERENTIAL RING GEAR BACKLASH

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  7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

    Click here

  8. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION

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  9. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

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  10. INSPECT TOTAL PRELOAD

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  11. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A001D3ZE03

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

      SST
      09308-00010

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


    1. A0018VBE07
      Text in Illustration
      *1 Disc

      Install SST to the differential carrier.

      SST
      09571-50010

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

    3. A001AFUE06

      Install a dial indicator to the rear differential carrier.

    4. Tighten 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 clearance 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. A0019AP

      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 SST bolt.

      Note

      Do not remove SST.

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


    1. A001EBEE07

      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. A001EIQ

      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.

  14. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE LH


    1. A001BVXE04
      Text in Illustration
      *a Turn

      Tighten 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. A001F61E02

      Remove the 2 bolts and SST.

  15. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE RH


    1. A001ASO

      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 purposes, take note of 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.

  16. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A001EYY

      Remove the rear differential case sub-assembly.

      Note

      Do not damage the case bearing.

  17. REMOVE REAR DRIVE PINION NUT


    1. A001DK6E02

      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. A001DDQE04
      Text in Illustration
      *a Turn
      *b Hold

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

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

  18. REMOVE REAR DRIVE PINION COMPANION FLANGE


    1. A001EAIE01
      Text in Illustration
      *a Turn
      *b Hold

      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 SST center bolt before use.

  19. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

    Tech Tips

    Perform this procedure only when the dust deflector is damaged.


    1. A001E22E01

      Using SST and a press, remove the dust deflector.

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

  20. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

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  21. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A001A9A

      Remove the drive pinion oil slinger.

  22. REMOVE DIFFERENTIAL DRIVE PINION


    1. A001FCT

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

      Note

      Do not drop the drive pinion.

  23. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A001CF8

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

  24. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A001EGF

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

    2. A001DZ4

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

  25. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A001CA1E03

      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. A001FP2

      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 rear differential drive pinion plate washer.

  26. REMOVE DIFFERENTIAL RING GEAR


    1. A0019ETE03
      Text in Illustration
      *a Matchmark

      Put matchmarks on the ring gear and differential case.

    2. Remove the 10 ring gear set bolts.

    3. A001FH1

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

      Note

      Do not damage the ring gear.

  27. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY

    Click here

  28. REMOVE REAR DIFFERENTIAL CASE BEARING

    Tech Tips

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


    1. A001DQ9E03
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the case bearing inner races 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.

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

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