REAR DIFFERENTIAL CARRIER ASSEMBLY(w/ Differential Lock) DISASSEMBLY

PROCEDURE


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


    1. B001Y41E40
      *1 Vertical Runout:
      *2 Lateral Runout:
      *3 35 mm (1.38 in.)

      Using a dial indicator, measure the vertical and lateral runout of the companion flange.

      Maximum Runout
      Runout 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.

  2. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR


    1. A01XC4W

      Using a dial indicator, measure the runout of the ring gear.

      Maximum runout
      0.05 mm (0.00197 in.)

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

  3. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01X4NT

      Using a dial indicator, measure the backlash of the ring gear.

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

      Tech Tips

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

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

  4. REMOVE NO. 1 TRANSFER INDICATOR SWITCH


    1. A01X6X9

      Remove the switch and gasket.

  5. REMOVE REAR DIFFERENTIAL LOCK COVER


    1. A01X1MO

      Remove the 3 bolts.

    2. Using a brass bar and hammer, tap on the cover to remove it.

  6. REMOVE DIFFERENTIAL LOCK SHIFT ACTUATOR


    1. A01X0QT

      Remove the 4 bolts.

    2. A01X4GD

      Remove the shift fork shaft bolt.

    3. Using a screwdriver, pull out the actuator and remove the sleeve and shift fork.

  7. REMOVE DRIVE PINION COMPANION FLANGE REAR NUT


    1. B001YKVE14

      Using SST and a hammer, unstake the nut.

      SST
      09930-00010
    2. B001X9YE02

      Using SST to hold the companion flange, remove the nut.

      SST
      09330-00021   ( 09330-00030 )

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


    1. B001YL0E02

      Using SST, remove the companion flange.

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

  9. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. B001YN3E02

      Using SST, remove the oil seal.

      SST
      09308-10010

  10. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  11. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B001Z8VE03

      Using SST, remove the bearing (inner race).

      SST
      09556-22010

      If the front bearing is damaged or worn, replace the bearing.

  12. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. B001XGWE03
      *1 Matchmark

      Place matchmarks on the bearing caps and differential carrier.

    2. Remove the 4 bolts and 2 bearing caps.

    3. B001ZGBE03

      Using SST and a hammer, remove the plate washers.

      SST
      09504-22011

      Tech Tips

      Measure the thickness of each plate washer and note it down.

    4. B001XX1E01

      Remove the differential case with the side bearing (outer race) from the differential carrier.

      Tech Tips

      Tag the bearing outer races to show the location for reassembly.

  13. REMOVE DIFFERENTIAL DRIVE PINION

  14. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

  15. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B001Z0UE01

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

      SST
      09950-00020

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

  16. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

  17. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01X7BD

      Using a brass bar and hammer, tap out the bearing (outer race).

  18. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01XAFU

      Using a brass bar and hammer, tap out the bearing (outer race).

  19. REMOVE DIFFERENTIAL RING GEAR


    1. B001Y7QE06
      *1 Matchmark

      Place matchmarks on the ring gear and differential case.

    2. Remove the 12 ring gear set bolts.

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

  20. INSPECT RUNOUT OF DIFFERENTIAL CASE


    1. Place the bearing outer races on their respective bearings.

      Tech Tips

      Do not interchange the left and right outer races.

    2. Install the assembled plate washers to the side bearing.

    3. Install the differential case to the differential carrier.

      Tech Tips

      If it is difficult to install the differential case to the carrier, replace the plate washer with a thinner one.

      However, select a plate washer that allows no clearance between it and the carrier.

    4. Align the matchmarks on the bearing caps and differential carrier.

    5. Install and uniformly tighten the 4 bolts a little at a time.

    6. A01XC3J

      Using a dial indicator, measure the differential case runout.

      Maximum case runout
      0.04 mm (0.00157 in.)

      If the runout is more than the maximum, replace the differential case and side bearings as a set.

    7. Remove the differential case.

  21. DISASSEMBLE DIFFERENTIAL CASE


    1. B001ZWNE03
      *1 Matchmark

      Place matchmarks on the differential case and differential cover.

    2. Using a T10 "TORX" socket, remove the 5 set bolts and 3 pinion shaft pins.

    3. Separate the cover and case.

    4. Remove the 2 side gears, 2 side gear thrust washers, 4 pinion gears, 4 pinion gear thrust washers, 3 pinion shafts and holder from the differential case.

  22. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. B001ZA4E03

      Using SST, remove the side bearing.

      SST
      09950-40011   ( 09952-04010, 09953-04020, 09954-04010, 09955-04061 )

      Tech Tips

      Fix the claws of SST to the notches in the differential case.

  23. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. B001W48E03

      Using SST, 4 bolts and a press, remove the bearing.

      SST
      09950-60010   ( 09951-00580 )
      09950-70010   ( 09951-07150 )