REAR DIFFERENTIAL CARRIER ASSEMBLY(for Pre-Runner) DISASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

The following procedures are for BD20 (w/o Differential Lock).

PROCEDURE


  1. SECURE REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. B003MHU

      Secure the differential carrier.

  2. INSPECT REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. B003LE1C06
      *a 30 mm (1.18 in.)

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

      Maximum Runout
      Runout Maximum
      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


    1. B003M8XC01
      *a 92 mm (3.62 in.)

      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

    B003N5U

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

      Backlash
      0.13 to 0.18 mm (0.00512 to 0.00708 in.)

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

        Tech Tips

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

  5. INSPECT TOTAL PRELOAD

    Click here

  6. REMOVE REAR DRIVE PINION NUT

    Click here

  7. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY WITH DUST DEFLECTOR

    Click here

  8. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

    Click here

  9. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

    Click here

  10. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B003J9LN01

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

      SST
      09556-22010

  11. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. B003NKS

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

  12. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. B003PUQC01
      *a Matchmark

      Place matchmarks on the bearing cap and differential carrier.

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

    3. Remove the 2 rear differential bearing adjusting nuts.

    4. B003RZQ

      Remove the rear differential case assembly from the differential carrier.

      Tech Tips

      Tag the 2 rear differential case bearings (outer) so that they can be reinstalled in the correct locations.

  13. REMOVE DIFFERENTIAL DRIVE PINION


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

  14. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B003S4YN04

      Using SST and a press, press out the rear drive pinion rear tapered roller bearing (inner) and rear differential drive pinion plate washer from the differential drive pinion.

      SST
      09950-00020

      Note

      Do not drop the differential drive pinion.

      Tech Tips

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

  15. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B003RIJN02

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

      SST
      09308-00010

    2. Using a brass bar and hammer, tap out the differential oil storage ring from the differential carrier.

      Tech Tips

      If the bearing is damaged during removal, replace it.

  16. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B003RJN

      Using a brass bar and hammer, tap out the rear drive pinion rear tapered roller bearing (outer) from the differential carrier.

      Tech Tips

      If the bearing is damaged during removal, replace it.

  17. REMOVE DIFFERENTIAL RING GEAR


    1. B003RFRC01
      *a Matchmark

      Place matchmarks on the differential ring gear and differential case.

    2. Remove the 10 differential ring gear set bolts.

    3. B003KC4

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

  18. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT

    If the ring gear runout is within the specified value (refer to the "Inspect Runout of Differential Ring Gear" procedure above), skip this step.


    1. Install the rear differential case bearings (outer) to the differential case.

    2. Install the differential case to the differential carrier.

    3. Install the 2 adjusting nuts.

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

      Torque:
      85.3 N*m  { 870 kgf*cm, 63 ft.*lbf }
    5. B003OTFC01
      *a 87 mm (3.43 in.)

      Using a dial indicator, measure the differential case runout.

      Maximum runout
      0.07 mm (0.00276 in.)

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

    7. Remove the 2 rear differential bearing adjusting nuts.

    8. Remove the differential case assembly.

    9. Remove the rear differential case bearings (outer).

  19. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. B003QTXC01
      *a Turn
      *b Hold

      Using SST, remove the 2 rear differential case bearings (inner) 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 )

      Tech Tips

      Do not remove the rear differential case bearings when not replacing the differential case.

  20. DISASSEMBLE DIFFERENTIAL CASE


    1. B003MIU

      Using a chisel and hammer, unstake the differential case.

    2. B003PT1

      Using a pin punch and hammer, tap out the straight pin.

    3. B003QEM

      Remove the following parts from the differential case.


      1. B003S4IC04
        *1 Side Gear
        *2 Rear No. 1 Differential Side Gear Thrust Washer
        *3 Pinion Shaft
        *4 Pinion Gear
        *5 Pinion Gear Thrust Washer

        Side gear (2 pieces)

      2. Rear No. 1 differential side gear thrust washer (2 pieces)

      3. Pinion shaft

      4. Pinion gear (2 pieces)

      5. Pinion gear thrust washer (2 pieces)

    4. Using a chisel and hammer, unstake the differential case.

  21. INSPECT DIFFERENTIAL GEAR KIT


    1. Check that the differential pinion and differential gear are not damaged.


      • If the differential pinion or differential side gear is damaged, replace the differential gear kit.

  22. INSPECT DIFFERENTIAL CASE


    1. Check that the differential case is not damaged.


      • If the differential case is damaged, replace it.