DIFFERENTIAL CARRIER ASSEMBLY 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. A01E2JX

      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

    A01DX8D

    1. 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. 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 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 )

  8. 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.

  9. 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

  10. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01DZDA

      Remove the oil slinger from the drive pinion.

  11. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01E1CNE01

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

      SST
      09556-22010

  12. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK


    1. A01DZFW

      Remove the 2 bolts and 2 adjusting nut locks.

  13. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A01DYE9E01
      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. A01DXY5

      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.

  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. A01E25UE01

      Using SST and a press, press out the roller bearing (inner) and drive pinion plate washer 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 DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01E2ZWE01

      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.

  17. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01E00X

      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.

  18. REMOVE DIFFERENTIAL RING GEAR


    1. A01DVNWE01
      Text in Illustration
      *1 Matchmark

      Place matchmarks on the ring gear and differential case.

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

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

    4. A01E1CO

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

  19. 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).

  20. 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.

  21. DISASSEMBLE DIFFERENTIAL CASE (for 2 Pinion Gear Type)


    1. A01E020

      Using a chisel and hammer, unstake the differential case.

    2. A01DV08

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

    3. A01E0UI

      Remove the following parts from the differential case.


      • A01E1MEE01

        (1) Side gear (2 pieces)

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

      • (3) Pinion shaft

      • (4) Pinion gear (2 pieces)

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

    4. Using a chisel and hammer, unstake the differential case.

  22. DISASSEMBLE DIFFERENTIAL CASE (for LSD)


    1. A01DYF0E01
      Text in Illustration
      *1 Matchmark

      Place matchmarks on the LH and RH cases.

    2. Remove the 8 bolts.

      Note

      Diametrically loosen and remove the bolts in several passes.

    3. A01DW5WE01

      Remove the following parts from the differential cases.


      • (1) Side gear (2 pieces)

      • (2) No. 1 Side gear thrust washer (6 pieces)

      • (3) Clutch plate (6 pieces)

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

      • A01DVH5E01

        (5) Spring retainer RH

      • (6) Spring retainer LH

      • (7) Compression spring

      • (8) Pinion gear (4 pieces)

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

      • (10) Spider

  23. INSPECT REAR NO. 1 DIFFERENTIAL SIDE GEAR THRUST WASHER (for LSD)


    1. A01DUYK

      Using a micrometer, measure the thickness of the thrust washer. Also, check that there is no bare metal.

      Standard thickness
      1.77 to 1.86 mm (0.0697 to 0.0732 in.)

      • If necessary, replace the thrust washers.

        Tech Tips

        If replacing the thrust washer, also replace the clutch plate that it contacts.

  24. INSPECT CLUTCH PLATE (for LSD)


    1. A01E08J

      Using a micrometer, measure the thickness of the clutch plate. Also, check that there is no abnormal wear.

      Standard thickness
      1.57 to 1.63 mm (0.0619 to 0.0641 in.)

      • If necessary, replace the clutch plate.

  25. INSPECT COMPRESSION SPRING (for LSD)


    1. A01DYJY

      Using a vernier caliper, measure the free length of the spring.

      Minimum free length
      27.02 mm (1.063 in.)

      • If the length is less than the minimum, replace the spring.

  26. 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.

  27. INSPECT DIFFERENTIAL CASE


    1. Check that the differential case is not damaged.


      • If the differential case is damaged, replace it.