REAR DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY

Tech Tips

Use an overhaul stand as necessary.


  1. SEPARATE ELECTRO MAGNETIC CONTROL COUPLING WIRE HARNESS


    1. A019LGN

      Disengage the claw and separate the electro magnetic control coupling wire harness form the 2 clamps.

  2. REMOVE CONNECTOR BRACKET


    1. A019K2E

      Remove the 3 bolts and 2 connector brackets from the rear differential carrier.

    2. Remove the 2 clamps from the 2 connector brackets.

  3. REMOVE REAR DIFFERENTIAL FILLER PLUG


    1. A019O8W

      Remove the rear differential filler plug and gasket.

  4. INSPECT RUNOUT OF ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY


    1. A019O8LE01

      Install a dial indicator and magnetic base perpendicular to the inner side of the electro magnetic control coupling sub-assembly as shown in the illustration.

    2. Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the vertical runout.

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

      If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

    3. Install a dial indicator and magnetic base perpendicular to the electro magnetic control coupling sub-assembly as shown in the illustration.

    4. Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the lateral runout.

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

      If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

  5. REMOVE REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG


    1. A019KLQ

      Using a screwdriver, remove the rear differential carrier cover breather plug.

  6. REMOVE STUD BOLT


    1. A019L2DE14
      Text in Illustration
      *1 Upper Nut
      *2 Lower Nut
      *a Turn
      *b Hold

      Install 2 service nuts to the stud bolt.

      Recommended service nut
      Thread diameter
      10 mm (0.394 in.)
      Thread pitch
      1.0 mm (0.0394 in.)

    2. Lock the upper nut using the lower nut.

    3. Turn the lower nut and remove the other 3 stud bolts in the same way.

      Note

      Prevent foreign matter from entering to the electro magnetic control coupling sub-assembly.

      Tech Tips

      If the threads of the electro magnetic control coupling sub-assembly are damaged while removing the stud bolt, replace the electro magnetic control coupling sub-assembly with a new one.

  7. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR


    1. A019NX8E04
      Text in Illustration
      *1 Tape
      *a Matchmark

      Put matchmarks on the rear differential dust deflector and electro magnetic control coupling sub-assembly.

    2. Using a screwdriver, remove the rear differential dust deflector.

      Note


      • Pry around the circumference of the rear differential dust deflector uniformly to prevent deformation.

      • Do not damage the end surface of the electro magnetic control coupling sub-assembly.

      Tech Tips


      • Tape the screwdriver tip before use.

      • If the end surface of the electro magnetic control coupling sub-assembly are damaged while removing the rear differential dust deflector, replace the electro magnetic control coupling sub-assembly with a new one.

  8. REMOVE ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY


    1. A019LSA

      Remove the 4 bolts.

    2. Using a plastic hammer, lightly tap the electro magnetic control coupling sub-assembly to remove it from the rear differential carrier assembly.

  9. REMOVE CONICAL WASHER


    1. A019N2XE01
      Text in Illustration
      *1 Conical Washer

      Remove the conical washer from the rear differential carrier assembly.

  10. REMOVE SPACER


    1. A019NGXE01
      Text in Illustration
      *1 Spacer

      Remove the spacer from the rear differential carrier assembly.

  11. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A019OE4E01

      Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a ring gear tooth tip.

    2. Using SST, hold the drive pinion in place.

      SST
      09556-16011

    3. Using SST, rotate the rear differential case assembly forward and backward, and measure the backlash.

      SST
      09564-32011
      Backlash
      0.13 to 0.25 mm (0.00512 to 0.00984 in.)

      Note

      Measure at 3 or more areas on the circumference of the ring gear.

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

  12. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A019PMHE01

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

      SST
      09556-16011
      Standard drive pinion preload
      1.5 to 2.5 N*m (16 to 25 kgf*cm, 14 to 22 in.*lbf)

      Tech Tips

      For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

      If the differential drive pinion preload is not within the specified range, adjust the differential drive pinion preload or repair as necessary.

  13. INSPECT TOTAL PRELOAD


    1. A019PMHE01

      Using SST and a torque wrench, inspect the total preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.

      SST
      09556-16011
      Standard total preload
      2.8 to 5.3 N*m (29 to 54 kgf*cm, 25 to 47 in.*lbf)

      Note

      For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

      If the total preload is not within the specified range, adjust the total preload or repair as necessary.

  14. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A019NN3E01

      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. A019KNNE01
      Text in Illustration
      *1 Diaphragm Oil Seal

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

      SST
      09308-00010

  16. REMOVE REAR DRIVE PINION NUT


    1. A019PLDE02
      Text in Illustration
      *1 Rear Drive Pinion Nut

      Using SST and a hammer, unstake the rear drive pinion nut.

      SST
      09930-00010

      Note


      • Use SST with the tapered part facing against the shaft.

      • Do not modify the SST tip with a grinder or equivalent.

      • Fully unstake the rear drive pinion nut.

    2. A019N70E03

      Using SST, hold the differential drive pinion in place and remove the rear drive pinion nut from the differential drive pinion.

      SST
      09556-16011
      09564-16020

  17. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A019JTNE01
      Text in Illustration
      *1 Rear Drive Pinion Front Tapered Roller Bearing (Inner Race)

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

      SST
      09556-40010

  18. REMOVE DIFFERENTIAL SIDE BEARING RETAINER


    1. A019LD8

      Remove the 10 bolts from the rear differential carrier assembly.

    2. A019MII

      Using a brass bar and a hammer, disengage the 2 pins and remove the differential side bearing retainer from the rear differential carrier assembly.

      Note

      Set the brass bar on the ribbed part of the differential side bearing retainer.

  19. REMOVE REAR DIFFERENTIAL CASE ASSEMBLY


    1. A019N8W

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

  20. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A019MDU

      Remove the 2 bolts and rear differential breather plug oil deflector from the rear differential carrier.

  21. REMOVE DIFFERENTIAL DRIVE PINION


    1. A019KK4

      Remove the differential drive pinion from the rear differential carrier.

  22. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A019MV5

      Remove the rear differential drive pinion oil slinger from the differential drive pinion.

  23. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A019LA5

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

  24. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A019PBQE01

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

      SST
      09950-00020

      Note


      • If the differential drive pinion or differential ring gear is damaged, replace them both.

      • Do not drop the differential drive pinion.

    2. Remove the rear differential drive pinion plate washer.

  25. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A019K55E01
      Text in Illustration
      *1 Rear Drive Pinion Front Tapered Roller Bearing (Outer Race)

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

      SST
      09387-00041   ( 09387-01030, 09387-01040 )
      09387-02020

  26. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A019MXR

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

      Note

      Set the brass bar on the notch.

  27. REMOVE REAR DIFFERENTIAL CASE BEARING (for LH Side)


    1. A019OVFE01
      Text in Illustration
      *1 Rear Differential Case Bearing (Outer Race)
      *2 Rear Differential Side Gear Shaft Plate Washer

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

      SST
      09950-60010   ( 09951-00540 )
      09950-70010   ( 09951-07100 )

  28. REMOVE REAR DIFFERENTIAL CASE BEARING (for RH Side)


    1. A019NB0E01
      Text in Illustration
      *1 Rear Differential Case Bearing (Outer Race)
      *2 Rear Differential Side Gear Shaft Plate Washer

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

      SST
      09950-60010   ( 09951-00590 )
      09950-70010   ( 09951-07100 )

  29. REMOVE STRAIGHT PIN


    1. Remove the 4 straight pins from the rear differential carrier.

      A019L0Q

  30. REMOVE REAR DIFFERENTIAL CASE BEARING (for LH Side)

    Tech Tips

    Perform this step only when replacing the rear differential case bearing or rear differential case sub-assembly.


    1. A019NVHE01
      Text in Illustration
      *1 Rear Differential Case Bearing (Inner Race)

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

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00340 )

      Note

      Before using the SST center bolt, apply grease 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 race.

  31. REMOVE REAR DIFFERENTIAL CASE BEARING (for RH Side)

    Tech Tips

    Perform this step only when replacing the rear differential case bearing or rear differential case sub-assembly.


    1. A019L3LE01
      Text in Illustration
      *1 Rear Differential Case Bearing (Inner Race)

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

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00370 )

      Note

      Before using the SST center bolt, apply grease 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 race.

  32. REMOVE DIFFERENTIAL RING GEAR


    1. A019OPUE01
      Text in Illustration
      *1 Matchmark

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

    2. Remove the 12 ring gear set bolts.

    3. Using a plastic hammer, lightly and uniformly tap the outer circumference of the differential ring gear to remove it from the rear differential case sub-assembly.

      Note


      • Do not drop the differential ring gear.

      • If the differential drive pinion or differential ring gear is damaged, replace them both.

      Tech Tips

      If it is difficult to remove, tap the outer circumference of the differential ring gear using a brass bar and a hammer.

  33. INSPECT DIFFERENTIAL PINION AND SIDE GEAR


    1. Check the differential pinion gears and differential side gears for wear.

      If the differential pinion gears and differential side gears are damaged, replace the rear differential case sub-assembly.

  34. INSPECT DIFFERENTIAL CASE


    1. Check the differential case for cracks or damage.

      If the differential case is damaged, replace the rear differential case sub-assembly.