DIFFERENTIAL CARRIER ASSEMBLY (for DANA Made) DISASSEMBLY


  1. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY

    A01J6MI

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

    A01J5BHE03

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

      Maximum runout
      Runout Maximum
      Vertical runout 0.10 mm (0.0039 in.)
      Lateral runout 0.10 mm (0.0039 in.)

      • If the runout is greater than the maximum, replace the companion flange.

  3. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

    A01J4GB

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

      Maximum runout
      0.07 mm (0.0028 in.)

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

  4. INSPECT DIFFERENTIAL RING GEAR BACKLASH

    A01J3WS

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

      Standard backlash
      0.13 to 0.18 mm (0.0051 to 0.0071 in.)

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

        Tech Tips

        Perform the measurements at 3 or more positions around the side bearing preload.

  5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

    A01J34HE01

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

      Standard drive pinion preload (at start of torque)
      0.56 to 0.85 N*m (6 to 9 kgf*cm, 4.9 to 7.5 in.*lbf)

      • If necessary, disassemble and inspect the differential.

  6. INSPECT TOTAL PRELOAD

    A01J34HE01

    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.

      Tech Tips

      A bolt without a torque specification is shown in the service data Click here.


      • If necessary, disassemble and inspect the differential.

  7. REMOVE REAR DRIVE PINION NUT

    A01J5KSE01

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

      SST
      09930-00010   ( 09931-00010, 09931-00020 )
    2. A01J3XKE03

      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

    A01J7BWE01

    1. Using SST, remove the companion flange.

      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 DUST DEFLECTOR

    A01J3P3E02

    1. Using SST and a press, press out the dust deflector.

      SST
      09950-60010   ( 09951-00380 )
      09950-70010   ( 09951-07150 )
      09950-00020

      Note

      Do not drop the companion flange.

  10. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

    A01J6CLE02

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

      SST
      09308-10010

  11. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  12. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    A01J5NOE01

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

      SST
      09556-22010

  13. REMOVE DIFFERENTIAL CASE ASSEMBLY

    A01J6SGE01

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

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

    3. Remove the 2 side shims.

    4. A01J6V6E01

      Remove the rear differential case assembly from the differential carrier.

      Tech Tips

      Tag the 2 case bearing outer races to show the location for reassembly.

  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

    A01J4WME01

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

      SST
      09950-00020

      Note

      Do not drop the drive pinion.

      Tech Tips

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

  16. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

  17. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    A01J6KOE01

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

      SST
      09308-00010

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

      Tech Tips

      If the bearing is damaged during removal, replace it.

  18. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    A01J2ZEE01

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

      Tech Tips

      If the bearing is damaged during removal, replace it.

  19. REMOVE DIFFERENTIAL RING GEAR

    A01J7GJE01

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

    2. Remove the 10 ring gear set bolts.

    3. A01J6I6E02

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

  20. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT

    A01J4V7

    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:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

    4. Using a dial indicator, measure the differential case runout.

      Maximum runout
      0.07 mm (0.0028 in.)

    5. Remove the differential case.

    6. Remove the rear differential case bearing.

  21. REMOVE REAR DIFFERENTIAL CASE BEARING

    A01J4LPE02

    1. Using SST, remove the 2 bearings 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 bearing when not replacing the differential case.

  22. INSPECT DIFFERENTIAL PINION AND SIDE GEAR


    1. Check that the differential pinion and differential side gear are not worn.


      • If the differential pinion or differential side gear is not worn, replace the differential.

  23. INSPECT DIFFERENTIAL CASE

    A01J526E02

    1. Measure the side gear backlash.


      1. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case.

        Standard backlash
        0.05 to 0.20 mm (0.0020 to 0.008 in.)

        • If the backlash is not within the specified range, replace the differential case with a new one.