REAR DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY

CAUTION / NOTICE / HINT

Note

Before installation of each part, thoroughly clean and dryit. Then apply gear oil to it. Do not use alkaline chemicals to clean aluminum parts, rubber parts or ring gear setbolts. Also, do not use non-residue solvent or other cleaning oils to clean O-rings, oil seals or rubber parts.

PROCEDURE


  1. SECURE REAR DIFFERENTIAL CARRIER SUB-ASSEMBLY


    1. Secure the rear differential carrier sub-assembly to the overhaul attachment.

  2. REMOVE STUD BOLT


    1. Using 2 nuts, remove the 4 stud bolts from the transmission coupling assembly.

  3. REMOVE REAR DIFFERENTIAL FILLER PLUG


    1. A01V8A2

      Using a 10 mm socket hexagon wrench, remove the rear differential filler plug and gasket.

  4. REMOVE REAR DIFFERENTIAL DRAIN PLUG


    1. A01VAP8

      Using a 10 mm socket hexagon wrench, remove the rear differential drain plug and gasket.

  5. REMOVE REAR DIFFERENTIAL CARRIER COVER PLUG


    1. A01V9GD

      Using an 8 mm socket hexagon wrench, remove the rear differential carrier cover plug.

  6. REMOVE REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG


    1. A01V97R

      Using a chisel and hammer, slightly lift up the rear differential carrier cover breather plug.

    2. Using a screwdriver, lightly pry up and remove the rear differential carrier cover breather plug.

  7. INSPECT TRANSMISSION COUPLING ASSEMBLY


    1. A01V7XKC06
      *a Vertical Runout
      *b Lateral Runout

      Attach a lever probe to a dial indicator and set the probe at a right angle to the inner surface of the transmission coupling assembly.

    2. Using SST, rotate the transmission coupling assembly forward and in reverse and measure the vertical runout.

      SST
      09564-32011
      Maximum
      0.06 mm (0.00236 in.)

      Tech Tips

      If the measurement is more than the maximum, replace the transmission coupling assembly.

    3. Set the dial indicator at a right angle to the transmission coupling assembly in the position shown in the illustration.

    4. Using SST, rotate the transmission coupling assembly forward and in reverse and measure the lateral runout.

      SST
      09564-32011
      Maximum
      0.07 mm (0.00276 in.)

      Tech Tips

      If the measurement is more than the maximum, replace the transmission coupling assembly.

  8. REMOVE TRANSMISSION COUPLING ASSEMBLY


    1. A01V8UV

      Remove the 4 bolts, and, using a brass bar and plastic-faced hammer, lightly tap the transmission coupling assembly to remove it from the rear differential carrier assembly.

      Note


      • Put the brass bar against the rib of the transmission coupling assembly.

      • When removing the transmission coupling assembly, be careful not to scratch the mating surface.

      Tech Tips

      To prevent the transmission coupling assembly from falling, leave 2 of the bolts screwed in by 5 or 6 threads.

    2. A01V905

      Using a snap ring expander, remove the snap ring.

    3. A01V8MX

      Remove the 4WD linear solenoid from the yoke.

    4. A01V6ZR

      Remove the O-ring from the 4WD linear solenoid.

    5. A01VACG

      Using a 5 mm socket hexagon wrench, remove the 2 bolts and yoke from the rear differential carrier assembly.

  9. REMOVE TRANSMISSION COUPLING CONICAL SPRING WASHER


    1. A01VAGUC01
      *1 Transmission Coupling Conical Spring Washer

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

  10. REMOVE TRANSMISSION COUPLING SHIM


    1. A01VAANC01
      *1 Transmission Coupling Shim

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

  11. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01V9NUC09
      *a Turn
      *b Hold

      Insert a dial indicator into the rear differential side gear shaft oil seal hole, and place it perpendicular to the edge of a ring gear tooth.

    2. Using SST, secure the differential drive pinion.

      SST
      09556-52010

    3. Using SST, check the backlash while rotating the rear differential case assembly forward and in reverse.

      SST
      09564-32011
      Standard
      0.088 to 0.208 mm (0.00347 to 0.00818 in.)

      Note

      Measure the ring gear at 3 or more locations.

  12. INSPECT DIFFERENTIAL DRIVER PINION PRELOAD


    1. A01V6QQE01

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

      SST
      09556-52010
      Standard
      0.77 to 1.26 N*m (8 to 12 kgf*cm, 7 to 11 in.*lbf)

  13. INSPECT TOTAL PRELOAD


    1. A01V6QQE01

      Using SST and a torque wrench, measure the preload (at the start of torque) with the teeth of the drive pinion and differential ring gear in contact.

      SST
      09556-52010
      Standard
      Total preload = drive pinion preload + 0.58 to 1.01 N*m (6 to 10 kgf*cm, 5 to 8 in.*lbf)

      Note

      Measure the preload after rotating the case bearing several times in the forward and reverse directions to make sure the bearing is operating correctly.

  14. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01V7P4C01
      *1 Rear Differential Side Gear Shaft Oil Seal

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

      SST
      09308-00010

  15. REMOVE DIAPHRAGM OIL SEAL


    1. A01V7JJC01
      *1 Diaphragm Oil Seal
      *a Turn
      *b Hold

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

      SST
      09308-10010

  16. REMOVE REAR DRIVE PINION NUT


    1. A01V8MPE01

      Using SST and a hammer, loosen the staked part of the rear drive pinion nut.

      SST
      09930-00010

      Note


      • Use SST with the tapered surface facing the shaft side.

      • Do not grind the end of SST with a grinder or other tool.

      • Completely loosen the staked part of the rear drive pinion nut.

      • Do not damage the threads of the differential drive pinion.

    2. A01VAAQC01
      *a Turn
      *b Hold

      Using SST, secure the differential drive pinion and remove the rear drive pinion nut from the differential drive pinion.

      SST
      09556-52010

  17. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01VA3FC04
      *a Turn
      *b Hold

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

      SST
      09556-30010

  18. REMOVE DIFFERENTIAL SIDE BEARING RETAINER


    1. A01V991

      Remove the 8 bolts.

    2. A01V86K

      Using a brass bar and hammer, lightly tap the differential side bearing retainer and remove it.

      Note


      • Put the brass bar against the rib of the differential side bearing retainer.

      • When removing the differential side bearing retainer, be careful not to scratch the mating surface.

      Tech Tips

      Prevent the differential side bearing retainer from falling by screwing in 2 bolts by 5 or 6 threads.

  19. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01V8ZE

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

  20. REMOVE DIFFERENTIAL DRIVE PINION


    1. A01V837

      Remove the differential drive pinion from the rear differential carrier sub-assembly.

      Note

      If either the rear differential drive pinion or the differential ring gear has been scratched, replace both.

  21. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01V8BZ

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

  22. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01V91OE01

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

      SST
      09950-00020

      Note

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

    2. Remove the rear differential drive pinion washer.

  23. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01V9KUC01
      *a Turn
      *b Hold

      Attach the claws of SST to the rear drive pinion front tapered roller bearing (outer race) from the notches in the differential carrier sub-assembly.

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

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

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

  24. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01V6XD

      Using a brass bar and hammer, uniformly lightly tap the rear drive pinion rear tapered roller bearing (outer race) and remove it.

      Note

      Put the brass bar into one of the notches.

  25. REMOVE REAR DIFFERENTIAL CASE BEARING RH


    1. A01VAAOC02
      *1 Rear Differential Side Gear Shaft Plate Washer
      *2 Rear Differential Case Bearing RH (Outer Race)

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

      SST
      09950-60010   ( 09951-00510, 09951-07100 )

  26. REMOVE REAR DIFFERENTIAL CASE BEARING LH


    1. A01V9DFC02
      *1 Rear Differential Side Gear Shaft Washer
      *2 Rear Differential Case Bearing LH (Outer Race)

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

      SST
      09950-60010   ( 09951-00460, 09951-07100 )

  27. REMOVE REAR DIFFERENTIAL CASE BEARING RH


    1. A01V93JC04
      *a Turn
      *b Hold

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

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011, 09951-00320 )

      Note

      Before using SST center bolt (09953-04020), apply 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 rear differential case bearing RH (inner race).

      • If the rear differential case bearing RH (inner race) is deformed, replace it with a new one.

  28. REMOVE REAR DIFFERENTIAL CASE BEARING LH


    1. A01VAL5C04
      *a Turn
      *b Hold

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

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011, 09951-00320 )

      Note

      Before using SST center bolt (09953-04020), apply 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 rear differential case bearing LH (inner race).

      • If the rear differential case bearing LH (inner race) is deformed, replace it with a new one.

  29. REMOVE DIFFERENTIAL RING GEAR


    1. A01V8CVC05
      *a Matchmark

      Mount the rear differential case sub-assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Put matchmarks on the rear differential case sub-assembly and differential ring gear.

    3. Remove the 10 rear differential case bolts.

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

      Tech Tips

      Place a cloth on the teeth side of the ring gear to prevent damage.

  30. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A01V9QS

      Using a 5 mm socket hexagon wrench, remove the 2 bolts and rear differential breather plug oil deflector.

  31. REMOVE STRAIGHT PIN


    1. Remove the 4 straight pins from the rear differential carrier sub-assembly.

      A01V8QQ