Part 1

Part 1 Of 2:

Part 2 Of 2:

DIFFERENTIAL CARRIER ASSEMBLY REAR
OVERHAUL
1. REMOVE REAR WHEEL
2. REMOVE ENGINE UNDER COVER ASSEMBLY
3. REMOVE ENGINE UNDER COVER NO.2 (W/ ENGINE UNDER COVER NO.2)
4. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
SST 09325-20010
5. REMOVE EXHAUST PIPE ASSEMBLY
6. REMOVE REAR DIFFERENTIAL FILLER PLUG
a. Using a hexagon wrench (10 mm), remove the filler plug and gasket.
7. REMOVE REAR DIFFERENTIAL DRAIN PLUG
a. Using a hexagon wrench (10 mm), remove the drain plug and gasket, and drain the oil
8. SEPARATE SPEED SENSOR REAR LH
9. SEPARATE SPEED SENSOR REAR RH

HINT: Removal procedure of the RH side is the same as that of the LH side

10. REMOVE REAR AXLE SHAFT LH NUT
SST 09930-00010
11. REMOVE REAR AXLE SHAFT RH NUT
SST 09930-00010

HINT: Removal procedure of the RH side is the same as that of the LH side.

12. SEPARATE STRUT ROD ASSEMBLY REAR
13. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.1 LH
14. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.1 RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

15. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.2 LH
16. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.2 RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

17. REMOVE REAR DRIVE SHAFT ASSEMBLY LH
18. REMOVE REAR DRIVE SHAFT ASSEMBLY RH

HINT: Removal procedure of the RH side is the same as that of the LH side

19. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY
20. REMOVE DIFFERENTIAL CARRIER ASSEMBLY REAR





a. Support the differential carrier assembly rear with a jack.
b. Remove the 2 bolts and 2 lock nuts, and separate the rear differential support No.1 from the rear suspension member sub-assembly.





c. Remove the 3 bolts and differential carrier assembly rear from the rear suspension member sub-assembly.

NOTICE: Be careful not to drop the differential carrier assembly rear.





21. REMOVE REAR DIFFERENTIAL SUPPORT NO.1
a. Remove the 2 bolts, 2 lock nuts and rear differential support No.1 from the differential carrier assembly rear.





22. REMOVE REAR DIFFERENTIAL CARRIER COVER
a. Remove the 8 bolts from the carrier cover.
b. Using a brass bar and a hammer, separate the carrier cover from differential carrier assembly.
c. Remove the breather plug from the differential carrier cover.
23. FIX DIFFERENTIAL CARRIER ASSEMBLY REAR





24. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
a. Using a dial gauge, check the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
If the runout is greater than the maximum, replace the ring gear with a new one.





25. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using a dial gauge, check the backlash of the ring gear.
Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.
26. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See step 64)





27. DIFFERENTIAL PINION AND SIDE GEAR BACKLASH
a. Using a dial gauge, check the backlash of the side gear while holding 1 pinion gear toward the differential case.
Backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 inch)
If the backlash is not within the specification, install the 2 side gear thrust washers of different thickness (See step 52).

HINT: Measure the backlash of the side gear with the side gear shaft installed.





28. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
a. Using a dial gauge, measure the runout of the companion flange vertically and horizontally.
Maximum runout: 0.10 mm (0.0039 inch)





29. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the drive pinion.
Preload (at starting): 0.6 to 0.9 Nm (6 to 9 kgf-cm, 5.2 to 7.8 inch lbs.)

HINT: This preload is within the backlash between the drive pinion and ring gear.





30. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the total preload.
Total preload (at starting): Drive pinion preload plus 0.3 to 0.5 Nm (3 to 5 kgf-cm, 2.6 to 4.3 inch lbs.)
Disassemble and inspect the differential as necessary.





31. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL
a. Using SST(s), remove the 2 oil seals from the housing.
SST 09308-00010
32. REMOVE REAR DRIVE PINION NUT





a. Using SST(s) and a hammer, unstake the staked part of the nut.
SST 09930-00010





b. Using SST(s) to hold the flange, remove the nut.
SST 09330-00021





33. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
a. Using SST(s), remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)





34. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST(s) and a press, remove the dust deflector.
SST 09950-60010 (09951-00360), 09950-70010 (09951-07150), 09950-00020





35. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST(s), remove the oil seal from the differential carrier.
SST 09308-10010
36. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER





37. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST(s), remove the front bearing from the drive pinion.
SST 09556-22010
38. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
39. REMOVE DIFFERENTIAL CASE ASSEMBLY





a. Align matchmarks on the bearing cap and differential carrier.
b. Remove the 4 bolts and 2 bearing caps.





c. Using SST(s) and a screwdriver, remove the 2 plate washers.
SST 09504-22011

HINT: Measure the thickness of the plate washers and note it down.





d. Remove the differential case assembly and the 2 bearing outer races from the differential carrier.

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

40. REMOVE DIFFERENTIAL DRIVE PINION





41. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST(s) and a press, remove the rear bearing from the drive pinion.
SST 09950-00020

HINT: If either the drive pinion or ring gear is damaged, replace both as a set.

b. Remove the plate washer.





42. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, remove the front bearing (outer race) from the carrier.





43. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, remove the rear bearing (outer race) from the carrier.





44. REMOVE DIFFERENTIAL RING GEAR
a. Align matchmarks on the ring gear and differential case.
b. Using a screwdriver and a hammer, unstake the 4 lock plates.
c. Remove the 8 ring gear set bolts and 4 lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.





45. INSPECT RUNOUT OF DIFFERENTIAL CASE ASSEMBLY
a. Install the differential case to the differential carrier.
b. Install the right and left bearing caps with the 4 bolts.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.)
c. Using a dial gauge, measure the differential case runout.
Maximum case runout: 0.07 mm (0.0028 inch)
d. Remove the differential case.





46. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST(s), remove the case bearing (LH) 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)





47. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST(s), remove the case bearing (RH) 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)
48. REMOVE REAR DIFFERENTIAL PINION SHAFT





a. Using a pin punch (5 mm) and a hammer, remove the straight pin.





b. Remove the differential pinion shaft. [A]
c. Remove the 2 differential pinion gears. [B]
d. Remove the 2 differential pinion thrust washers. [C]
e. Remove the 2 side gears. [D]
f. Remove the 2 side gear thrust washers. [E]
49. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
a. Check that there is no damage to the differential pinion gear and side gear.
If the differential pinion gear and/or side gear is damaged, replace them with new ones.
50. INSPECT DIFFERENTIAL CASE
a. Check that there is no damage to the differential case.
If the differential case is damaged, replace it.





51. INSTALL REAR DIFFERENTIAL PINION SHAFT
a. Install the 2 thrust washers to the 2 side gears.
b. Install the 2 side gears, 2 differential pinion gears, 2 differential pinion thrust washers and differential pinion shaft to the differential case.

HINT: Align the holes of the differential case and differential pinion shaft.





52. ADJUST DIFFERENTIAL PINION GEAR BACKLASH
a. Measure the side gear backlash while holding 1 pinion gear toward the differential case.
Backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 inch)
If the backlash is not within the specification, install the 2 side gear thrust washers of different thicknesses.

HINT: Refer to the following table to select 2 thrust washers.





Thrust washer thickness





b. Using a pin punch (5 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft.
c. Using a chisel and a hammer, stake the outside of the differential case pin hole.





53. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear to approximately 100°C (212°F) in boiling water.
c. Carefully take the ring gear out of the boiling water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.





e. Align the matchmarks on the ring gear and differential case.
f. Temporarily install 4 new lock plates and 8 bolts.
g. After the ring gear cools down enough, torque the 8 bolts uniformly.
Torque: 97 Nm (985 kgf-cm, 71 ft. lbs.)

HINT: Tighten the bolts, in diagonal order, a little at a time until they are all tightened.





h. Using a chisel and a hammer, stake the 4 lock plates.
1. Stake one claw so that it is flush against the flat surface of the bolt.
2. As for the other claw, stake it against the surface of the bolt head so as to act as a stopper if the bolt should start to loosen.





54. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST(s) and a press, install the case bearing (RH) to the differential case.
SST 09636-20010