DIFFERENTIAL CARRIER ASSEMBLY (w/ Differential Lock) DISASSEMBLY


  1. SECURE REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. A01DY29

      Secure the differential carrier.

  2. INSPECT REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01E280E01
      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
      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. A01DZ2X

      Using a dial indicator, measure 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. A01DX43

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

      Standard 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. A01DZCY

      Using a torque wrench, measure the preload.

      Standard Preload (Starting Torque)
      Item Specified Condition
      New bearing 1.1 to 1.6 N*m (12 to 16 kgf*cm, 10 to 14 in.*lbf)
      Reused bearing 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.

  6. INSPECT TOTAL PRELOAD


    1. A01DZCY

      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 bearing 0.4 to 0.5 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) + drive pinion preload
      Reused bearing 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 DIFFERENTIAL LOCK SHIFT ACTUATOR


    1. A01DW4E

      Remove the 2 bolts and rear differential lock actuator protector.

    2. Remove the differential breather bracket.

    3. A01E009

      Remove the bolt and actuator from the differential carrier.

    4. Remove the O-ring.

  8. REMOVE NO. 4 TRANSFER INDICATOR SWITCH


    1. A01DY8SE01
      Text in Illustration
      *1 Gasket
      *2 Switch

      Remove the switch and gasket.

  9. REMOVE REAR DIFFERENTIAL LOCK SHIFT FORK SHAFT

    A01E084E01
    Text in Illustration
    *1 Steel Ball
    *2 Spring Seat
    *3 Spring
    *4 Screw Plug

    1. Using a 6 mm hexagon wrench, remove the 2 screw plugs.

    2. Remove the spring seat, spring and steel ball.

    3. A01E07JE01
      Text in Illustration
      *1 Shift Fork Shaft
      *2 Pin Punch
      *3 Slotted Spring Pin

      Using a 5 mm pin punch and hammer, tap out the slotted spring pin from the shift fork shaft.

    4. A01DV5N

      Remove the 2 bolts from the shaft retainer.

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

    6. Remove the shift fork shaft.

  10. REMOVE REAR DRIVE PINION NUT


    1. A01DVN5E01

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

      SST
      09930-00010   ( 09931-00010, 09931-00020 )
    2. A01DWE9E01
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09330-00021   ( 09330-00030 )

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


    1. A01DW9H

      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.

  12. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. A01DZCPE01
      Text in Illustration
      *1 Oil Seal
      *2 Oil Slinger

      Using SST, remove the oil seal.

      SST
      09308-10010

  13. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01DZDA

      Remove the oil slinger from the drive pinion.

  14. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01E1G9E02
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09556-22010

  15. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01DYZM

      Remove the 2 bolts and 2 adjusting nut locks.

  16. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A01E2DOE01
      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. A01DWJ3

      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.

  17. REMOVE DIFFERENTIAL DRIVE PINION


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

  18. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01DV1QE01

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

      SST
      09308-00010

  19. REMOVE DIFFERENTIAL OIL STORAGE RING


    1. A01E2YI

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

  20. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01DZDP

      Remove the bearing spacer from the drive pinion.

  21. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01E2T0

      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.

  22. REMOVE DIFFERENTIAL RING GEAR


    1. A01E2SZE01
      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. A01E1GQ

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

  23. 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  { 870 kgf*cm, 63 ft.*lbf }
    5. A01E1S6

      Using a dial indicator, measure 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).

  24. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. A01E2NRE01

      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 bearings when not replacing the differential case.

  25. DISASSEMBLE DIFFERENTIAL CASE


    1. A01E1SQE01
      Text in Illustration
      *1 Matchmark

      Place matchmarks on the LH and RH cases.

    2. Remove the 8 bolts uniformly, a little at a time.

    3. A01E1HY

      Using a plastic-faced hammer, tap out the LH case from the RH case.

    4. Remove the rear differential lock sleeve from the differential case LH.

    5. A01DW5KE01

      Remove the following parts from the differential cases.


      • (1) Side gear (2 pieces)

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

      • (3) Spider

      • (4) Pinion gear (4 pieces)

      • (5) Pinion gear thrust washer (4 pieces)

  26. INSPECT REAR DIFFERENTIAL LOCK SLEEVE


    1. A01E1O7

      Install the sleeve to the differential case LH and check that it moves smoothly.

    2. Install the sleeve to the side gear and check that it moves smoothly.

  27. INSPECT SHIFT FORK AND SLEEVE


    1. A01E2P3

      Using a feeler gauge, measure the clearance between the shift fork and sleeve.

      Standard clearance (reference)
      0.15 to 0.35 mm (0.00591 to 0.0137 in.)

  28. INSPECT DIFFERENTIAL GEAR KIT


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


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

  29. INSPECT DIFFERENTIAL CASE


    1. Check that the differential case is not damaged.


      • If the differential case is damaged, replace it.