DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY


  1. SECURE REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. A01J5WQ

      Secure the differential carrier.

  2. INSPECT REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01J4U6E01
      Text in Illustration
      *a 30 mm (1.18 in.)

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

      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


    1. A01J79W

      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


    1. A01J4ZG

      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 DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01J34Z

      Using a torque wrench, measure the preload.

      Standard Preload (Starting Torque)
      Bearing Specified Condition
      New 1.1 to 1.6 N*m (12 to 16 kgf*cm, 10 to 14 in.*lbf)
      Reused 0.6 to 0.8 N*m (7 to 8 kgf*cm, 6 to 7 in.*lbf)

      • If the result is not as specified, adjust the preload Click here.

  6. INSPECT TOTAL PRELOAD


    1. A01J34Z

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

      Standard Total Preload
      Bearing Specified Condition
      New 0.4 to 0.5 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) + drive pinion preload
      Reused 0.4 to 0.5 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) + drive pinion preload

      • If the result is not as specified, adjust the preload.

  7. REMOVE REAR DRIVE PINION NUT


    1. A01J42JE01

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

      SST
      09930-00010   ( 09931-00010, 09931-00020 )
    2. A01J6L7E01
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09330-00021   ( 09330-00030 )

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


    1. A01J3YB

      Using SST, remove the companion flange with dust deflector.

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

      Note

      Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

  9. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01J7MEE01
      Text in Illustration
      *1 Oil Seal
      *2 Oil Slinger

      Using SST, remove the oil seal.

      SST
      09308-10010

  10. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01J3D4

      Remove the oil slinger from the drive pinion.

  11. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01J5EUE01

      Using SST, remove the roller bearing (inner) from the drive pinion.

      SST
      09556-22010

  12. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01J3L0

      Remove the 2 bolts and 2 adjusting nut locks.

  13. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A01J39AE01
      Text in Illustration
      *1 Matchmark

      Place matchmarks on the bearing cap and differential carrier.

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

    3. Remove the 2 adjusting nuts.

    4. A01J3OS

      Remove the differential case with the 2 rear differential case bearings from the differential carrier.

    5. Remove the 2 rear differential case bearings (outer) and adjusting nuts from the differential case.

      Tech Tips

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

  14. REMOVE DIFFERENTIAL DRIVE PINION


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

  15. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01J6ZTE01

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

      SST
      09950-00020

      Tech Tips

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

      Note

      Do not drop the drive pinion.

  16. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01J5IIE01

      Using SST, remove the roller bearing (outer) from the carrier.

      SST
      09308-00010

  17. REMOVE DIFFERENTIAL OIL STORAGE RING


    1. A01J75W

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

  18. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01J78X

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

      If the bearing is damaged during removal, replace it.

  19. REMOVE DIFFERENTIAL RING GEAR


    1. A01J2YSE01
      Text in Illustration
      *1 Matchmark

      Place matchmarks on the ring gear and differential case.

    2. Using a screwdriver and hammer, pry out the staked portions of the lock plates.

    3. Remove the 10 ring gear set bolts and 5 lock plates.

    4. A01J3GO

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

  20. 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 N*m  { 867 kgf*cm, 63 ft.*lbf }
    5. A01J35R

      Inspect the differential case runout.

      Maximum runout
      0.07 mm (0.00276 in.)

    6. Remove the 4 bolts and 2 bearing caps.

    7. Remove the 2 adjusting nuts.

    8. Remove the differential case.

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

  21. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. A01J3KFE01

      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 case bearings when not replacing the differential case.

  22. DISASSEMBLE DIFFERENTIAL CASE


    1. A01J3BA

      Using a chisel and hammer, unstake the differential case.

    2. A01J5Y7

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

    3. A01J3ZV

      Remove the following parts from the differential case.


      • A01J4PPE01

        (1) Pinion gear (2 pieces)

      • (2) Pinion gear thrust washer (2 pieces)

      • (3) Pinion shaft

      • (4) Side gear (2 pieces)

      • (5) Side gear thrust washer (2 pieces)

  23. 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.

  24. INSPECT DIFFERENTIAL CASE


    1. Check that the differential case is not damaged.


      • If the differential case is damaged, replace it.