REAR DIFFERENTIAL CARRIER ASSEMBLY (w/ Differential Lock) DISASSEMBLY


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


    1. A015987E12

      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. A0158EM

      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. A015BB5

      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. A0157I8

      Remove the switch and gasket.

  5. REMOVE REAR DIFFERENTIAL LOCK COVER


    1. A0157VI

      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. A015ARN

      Remove the 4 bolts.

    2. A0156PC

      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. A01572PE03

      Using SST and a hammer, unstake the nut.

      SST
      09930-00010
    2. A015CZTE02

      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. A0156MLE02

      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. A0157LSE02

      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. A0155UFE03

      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. A0155E0E02

      Place matchmarks on the bearing caps and differential carrier.

    2. Remove the 4 bolts and 2 bearing caps.

    3. A015B8NE02

      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. A015A2UE01

      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. A015B45E01

      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. A015BKZ

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

  18. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A015D66

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

  19. REMOVE DIFFERENTIAL RING GEAR


    1. A0159NZE02

      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. A015AFX

      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. A015CHWE02

      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. A0155NYE02

      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. A015CO8E02

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

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