REAR DIFFERENTIAL CARRIER ASSEMBLY(w/ Differential Lock) DISASSEMBLY

PROCEDURE


  1. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY IN PLACE

    A01XKJR

    1. Fix the rear differential carrier assembly to the overhaul attachment.

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

    A01XFHWE44
    Text in Illustration
    *a Vertical Runout
    *b Lateral Runout

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

      Distance from center to runout measurement point
      30 mm (1.18 in.)
      Maximum Runout
      Item 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.

  3. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

    A01XEEF

    1. Using a dial indicator, check the runout of the ring gear.

      Maximum runout
      0.07 mm (0.00276 in.)

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

  4. INSPECT DIFFERENTIAL RING GEAR BACKLASH

    A01XLCJ

    1. Using a dial indicator, check the backlash of the ring gear.

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

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

  5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

    B001FHM

    1. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

      Standard preload (at starting)
      0.88 to 1.98 N*m (9.0 to 20.2 kgf*cm, 7.8 to 17.5 in.*lbf)

      If necessary, disassemble and inspect the differential assembly.

  6. INSPECT TOTAL PRELOAD

    B001FHM

    1. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

    2. Using a torque wrench, measure the total preload.

      Standard Total Preload (at starting)
      Drive pinion preload plus 0.20 to 0.40 N*m (2.0 to 4.1 kgf*cm, 1.8 to 3.5 in.*lbf)

      If necessary, disassemble and inspect the differential.

  7. REMOVE DIFFERENTIAL LOCK SHIFT ACTUATOR

    B001E28

    1. Remove the 4 bolts and actuator from the differential carrier.

    2. Remove the O-ring.

  8. REMOVE DIFFERENTIAL LOCK INDICATOR SWITCH

    A01XK9A

    1. Remove the indicator switch and gasket.

  9. REMOVE REAR DIFFERENTIAL LOCK SHIFT FORK SHAFT

    A01XHAR

    1. Using a 6 mm hexagon wrench, remove the 2 screw plugs.

    2. Remove the spring seat, spring and ball.

    3. A01XCUR

      Using a 5 mm pin punch and hammer, remove the slotted pin.

    4. A01XI4M

      Remove the 2 bolts from the shaft retainer.

    5. Using a plastic-faced hammer, remove the shaft retainer.

    6. Remove the shift fork shaft.

    7. Remove the rear differential lock sleeve.

  10. REMOVE REAR DRIVE PINION NUT

    A01XLI5E15

    1. Using SST and a hammer, loosen the staked part of the 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.

      • Do not damage the threads of the drive pinion.

    2. A01XCY9E19

      Use SST to hold the drive pinion companion flange.

      SST
      09330-00021

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

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

    A01XMIEE19

    1. Using SST, remove the drive pinion companion flange.

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

      Note

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

  12. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

    A01XICGE17

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

      SST
      09308-10010

  13. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

    Note

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

  14. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (INNER)

    A01XKQOE15

    1. Using SST, remove the drive pinion tapered roller bearing from the drive pinion.

      SST
      09556-22010

      Note

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

  15. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (OUTER)

  16. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK

    A01XI08

    1. Remove the 2 bolts and 2 rear differential bearing adjusting nut locks.

  17. REMOVE DIFFERENTIAL CASE ASSEMBLY

    A01XKFEE05

    1. Place matchmarks on the bearing cap and differential carrier.

      Text in Illustration
      *a Matchmark

    2. Remove the 4 bolts and 2 differential bearing caps.

    3. Remove the 2 adjusting nuts.

    4. A01XEDA

      Remove the rear differential case sub-assembly and 2 case bearings from the differential carrier.

      Tech Tips

      Tag the 2 case bearing outer races so that they can be reinstalled in the correct locations.

  18. REMOVE DIFFERENTIAL DRIVE PINION

    B001HBH

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

  19. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING (INNER)

    A01XDKWE15

    1. Using SST and a press, remove the drive pinion tapered roller bearing from the drive pinion.

      SST
      09950-00020

      Tech Tips

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

      Note

      Do not drop the drive pinion.

  20. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER)

    A01XHE1

    1. Using a brass bar and hammer, remove the rear tapered roller bearing from the carrier.

      Tech Tips

      If the bearing is damaged during the removal, replace it.

  21. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

  22. REMOVE DIFFERENTIAL RING GEAR

    B001CTLE02

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

      Text in Illustration
      *a Matchmark

    2. Using a screwdriver and hammer, unstake the lock plates.

    3. Remove the 12 ring gear set bolts.

    4. A01XLOM

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

  23. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    A01XIVNE09

    1. Using SST, remove the front tapered roller bearing from the carrier.

      SST
      09308-00010

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

      Tech Tips

      If the bearing is damaged during the removal, replace it.

  24. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT

    A01XJ72

    1. Install the rear differential case bearing to the differential case.

    2. Install the differential case to the differential carrier.

    3. Install the 2 bearing caps to the differential carrier with the 4 bolts.

      Torque:
      103 N*m  { 1049 kgf*cm, 76 ft.*lbf }

    4. Inspect the differential case runout.

      Maximum runout
      0.07 mm (0.00276 in.)

    5. Remove the differential case.

    6. Remove the rear differential case bearing.

  25. REMOVE REAR DIFFERENTIAL CASE BEARING

    A01XF71E14

    1. Using SST, remove the 2 rear differential case bearings from the differential case.

      SST
      09950-40011   ( 09953-04020, 09951-04010, 09952-04010, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00500, 09951-00650, 09952-06010 )

  26. DISASSEMBLE DIFFERENTIAL CASE

    A01XMMWE08

    1. Place matchmarks on the LH and RH cases.

      Text in Illustration
      *a Matchmark

    2. Remove the 8 bolts.

    3. A01XKTD

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

    4. A01XE7EE10
      Text in Illustration
      *1 Side Gear
      *2 Side Gear Thrust Washer
      *3 Spider
      *4 Pinion Gear
      *5 Pinion Gear Thrust Washer

      Remove the parts shown in the illustration from the differential case.