REAR DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY

CAUTION / NOTICE / HINT

Note:

Before installation of each part, thoroughly clean and dryit. Then apply gear oil to it. Do not use alkaline chemicals to clean aluminum parts, rubber parts or ring gear setbolts. Also, do not use non-residue solvent or other cleaning oils to clean O-rings, oil seals or rubber parts.

PROCEDURE

  1. SECURE REAR DIFFERENTIAL CARRIER SUB-ASSEMBLY

    1. Secure the rear differential carrier sub-assembly to the overhaul attachment.

  2. REMOVE STUD BOLT

    1. Using 2 nuts, remove the 4 stud bolts from the transmission coupling assembly.

  3. REMOVE REAR DIFFERENTIAL FILLER PLUG

    1. C288367

      Using a 10 mm socket hexagon wrench, remove the rear differential filler plug and gasket.

  4. REMOVE REAR DIFFERENTIAL DRAIN PLUG

    1. C285350

      Using a 10 mm socket hexagon wrench, remove the rear differential drain plug and gasket.

  5. REMOVE REAR DIFFERENTIAL CARRIER COVER PLUG

    1. C110129

      Using an 8 mm socket hexagon wrench, remove the rear differential carrier cover plug.

  6. REMOVE REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG

    1. C110130

      Using a chisel and hammer, slightly lift up the rear differential carrier cover breather plug.

    2. Using a screwdriver, lightly pry up and remove the rear differential carrier cover breather plug.

  7. INSPECT TRANSMISSION COUPLING ASSEMBLY

    1. C110131C06

      *a

      Vertical Runout

      *b

      Lateral Runout

      Attach a lever probe to a dial indicator and set the probe at a right angle to the inner surface of the transmission coupling assembly.

    2. Using SST, rotate the transmission coupling assembly forward and in reverse and measure the vertical runout.

      09564-32011

      Maximum

      0.06 mm (0.00236 in.)

      Tip:

      If the measurement is more than the maximum, replace the transmission coupling assembly.

    3. Set the dial indicator at a right angle to the transmission coupling assembly in the position shown in the illustration.

    4. Using SST, rotate the transmission coupling assembly forward and in reverse and measure the lateral runout.

      09564-32011

      Maximum

      0.07 mm (0.00276 in.)

      Tip:

      If the measurement is more than the maximum, replace the transmission coupling assembly.

  8. REMOVE TRANSMISSION COUPLING ASSEMBLY

    1. C277166

      Remove the 4 bolts, and, using a brass bar and plastic-faced hammer, lightly tap the transmission coupling assembly to remove it from the rear differential carrier assembly.

      Note:

      • Put the brass bar against the rib of the transmission coupling assembly.

      • When removing the transmission coupling assembly, be careful not to scratch the mating surface.

      Tip:

      To prevent the transmission coupling assembly from falling, leave 2 of the bolts screwed in by 5 or 6 threads.

    2. C130574

      Using a snap ring expander, remove the snap ring.

    3. C130597

      Remove the 4WD linear solenoid from the yoke.

    4. C130359

      Remove the O-ring from the 4WD linear solenoid.

    5. C359041

      Using a 5 mm socket hexagon wrench, remove the 2 bolts and yoke from the rear differential carrier assembly.

  9. REMOVE TRANSMISSION COUPLING CONICAL SPRING WASHER

    1. C130897C01

      *1

      Transmission Coupling Conical Spring Washer

      Remove the transmission coupling conical spring washer from the rear differential carrier assembly.

  10. REMOVE TRANSMISSION COUPLING SHIM

    1. C130898C01

      *1

      Transmission Coupling Shim

      Remove the transmission coupling shim from the rear differential carrier assembly.

  11. INSPECT DIFFERENTIAL RING GEAR BACKLASH

    1. C110134C09

      *a

      Turn

      *b

      Hold

      Insert a dial indicator into the rear differential side gear shaft oil seal hole, and place it perpendicular to the edge of a ring gear tooth.

    2. Using SST, secure the differential drive pinion.

      09556-52010

    3. Using SST, check the backlash while rotating the rear differential case assembly forward and in reverse.

      09564-32011

      Standard

      0.088 to 0.208 mm (0.00347 to 0.00818 in.)

      Note:

      Measure the ring gear at 3 or more locations.

  12. INSPECT DIFFERENTIAL DRIVER PINION PRELOAD

    1. C110135E01

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

      09556-52010

      Standard

      0.77 to 1.26 N*m (8 to 12 kgf*cm, 7 to 11 in.*lbf)

  13. INSPECT TOTAL PRELOAD

    1. C110135E01

      Using SST and a torque wrench, measure the preload (at the start of torque) with the teeth of the drive pinion and differential ring gear in contact.

      09556-52010

      Standard

      Total preload = drive pinion preload + 0.58 to 1.01 N*m (6 to 10 kgf*cm, 5 to 8 in.*lbf)

      Note:

      Measure the preload after rotating the case bearing several times in the forward and reverse directions to make sure the bearing is operating correctly.

  14. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

    1. C130599C01

      *1

      Rear Differential Side Gear Shaft Oil Seal

      Using SST, remove the 2 rear differential side gear shaft oil seals from the rear differential carrier assembly.

      09308-00010

  15. REMOVE DIAPHRAGM OIL SEAL

    1. C110140C01

      *1

      Diaphragm Oil Seal

      *a

      Turn

      *b

      Hold

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

      09308-10010

  16. REMOVE REAR DRIVE PINION NUT

    1. C110138E01

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

      09930-00010

      Note:

      • Use SST with the tapered surface facing the shaft side.

      • Do not grind the end of SST with a grinder or other tool.

      • Completely loosen the staked part of the rear drive pinion nut.

      • Do not damage the threads of the differential drive pinion.

    2. C277167C01

      *a

      Turn

      *b

      Hold

      Using SST, secure the differential drive pinion and remove the rear drive pinion nut from the differential drive pinion.

      09556-52010

      09564-16020

  17. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    1. C110141C04

      *a

      Turn

      *b

      Hold

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

      09556-30010

  18. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

    1. C285334

      Remove the 8 bolts.

    2. C285335

      Using a brass bar and hammer, lightly tap the differential side bearing retainer and remove it.

      Note:

      • Put the brass bar against the rib of the differential side bearing retainer.

      • When removing the differential side bearing retainer, be careful not to scratch the mating surface.

      Tip:

      Prevent the differential side bearing retainer from falling by screwing in 2 bolts by 5 or 6 threads.

  19. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

    1. C110144

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

  20. REMOVE DIFFERENTIAL DRIVE PINION

    1. C110145

      Remove the differential drive pinion from the rear differential carrier sub-assembly.

      Note:

      If either the rear differential drive pinion or the differential ring gear has been scratched, replace both.

  21. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

    1. C110146

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

  22. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    1. C110147E01

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

      09950-00020

      Note:

      If the rear differential driver pinion or differential ring gear is damaged, replace them both.

    2. Remove the rear differential drive pinion washer.

  23. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

    1. C277168C01

      *a

      Turn

      *b

      Hold

      Attach the claws of SST to the rear drive pinion front tapered roller bearing (outer race) from the notches in the differential carrier sub-assembly.

      09612-65014

      09612-01020

      09612-01050

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

      09612-65014

      09612-01020

      09612-01050

  24. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

    1. C110149

      Using a brass bar and hammer, uniformly lightly tap the rear drive pinion rear tapered roller bearing (outer race) and remove it.

      Note:

      Put the brass bar into one of the notches.

  25. REMOVE REAR DIFFERENTIAL CASE BEARING RH

    1. C274519C02

      *1

      Rear Differential Side Gear Shaft Plate Washer

      *2

      Rear Differential Case Bearing RH (Outer Race)

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

      09950-60010

      09951-00510

      09950-70010

      09951-07100

  26. REMOVE REAR DIFFERENTIAL CASE BEARING LH

    1. C274520C02

      *1

      Rear Differential Side Gear Shaft Washer

      *2

      Rear Differential Case Bearing LH (Outer Race)

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

      09950-60010

      09951-00460

      09950-70010

      09951-07100

      09649-17010

  27. REMOVE REAR DIFFERENTIAL CASE BEARING RH

    1. C130602C04

      *a

      Turn

      *b

      Hold

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

      09950-40011

      09951-04010

      09952-04010

      09953-04020

      09954-04010

      09955-04061

      09957-04010

      09958-04011

      09950-60010

      09951-00320

      Note:

      Before using SST center bolt (09953-04020), apply oil to its threads and tip.

      Tip:

      • If the race remains on the rear differential case sub-assembly, repeat the step above to remove the rear differential case bearing RH (inner race).

      • If the rear differential case bearing RH (inner race) is deformed, replace it with a new one.

  28. REMOVE REAR DIFFERENTIAL CASE BEARING LH

    1. C130603C04

      *a

      Turn

      *b

      Hold

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

      09950-40011

      09951-04010

      09952-04010

      09953-04020

      09954-04010

      09955-04071

      09957-04010

      09958-04011

      09950-60010

      09951-00320

      Note:

      Before using SST center bolt (09953-04020), apply oil to its threads and tip.

      Tip:

      • If the race remains on the rear differential case sub-assembly, repeat the step above to remove the rear differential case bearing LH (inner race).

      • If the rear differential case bearing LH (inner race) is deformed, replace it with a new one.

  29. REMOVE DIFFERENTIAL RING GEAR

    1. C130563C05

      *a

      Matchmark

      Mount the rear differential case sub-assembly in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

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

    3. Remove the 10 rear differential case bolts.

    4. Using a plastic-faced hammer, lightly tap the periphery of the differential ring gear to remove it from the rear differential case sub-assembly.

      Tip:

      Place a cloth on the teeth side of the ring gear to prevent damage.

  30. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

    1. C110156

      Using a 5 mm socket hexagon wrench, remove the 2 bolts and rear differential breather plug oil deflector.

  31. REMOVE STRAIGHT PIN

    1. Remove the 4 straight pins from the rear differential carrier sub-assembly.

      C279492