Disassembly

DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY: DISASSEMBLY

DISASSEMBLY

1. REMOVE REAR DIFFERENTIAL CARRIER GASKET
2. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY

(a) Fix the rear differential carrier assembly.
3. REMOVE REAR DRIVE PINION NUT

(a) Using SST and a hammer, unstake the nut.
SST: 09930-00010

(b) Using SST to hold the drive pinion companion flange, remove the nut.
SST: 09330-00021
4. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

(a) Using SST, remove the drive pinion companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03030
5. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

(a) Using SST and a press, remove the dust deflector.
SST: 09950-60010
09951-00380
SST: 09950-70010
09951-07150
SST: 09950-00020
6. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

(a) Using SST, remove the oil seal from the differential carrier.
SST: 09308-10010
7. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
8. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Using SST, remove the drive pinion tapered roller bearing (inner) from the drive pinion.
SST: 09556-22010
9. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK

(a) Remove the 2 bolts and 2 rear differential bearing adjusting nut locks.
10. REMOVE DIFFERENTIAL CASE ASSEMBLY

(a) Place matchmarks on the bearing cap and differential carrier.
(b) Remove the 4 bolts and 2 differential bearing caps.
(c) Remove the 2 adjusting nuts.

(d) Remove the rear differential case assembly and 2 bearing outer races from the differential carrier assembly.
HINT: Tag the 2 bearings outer races to show the locations for reassembly.

11. REMOVE DIFFERENTIAL DRIVE PINION

(a) Remove the differential drive pinion and bearing spacer from the differential carrier.
12. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using SST and a press, remove the drive pinion tapered roller bearing (inner) from the drive pinion.
SST: 09950-00020
If either the drive pinion or ring gear is damaged, replace them as a set.
13. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER
(a) Remove the plate washer from the drive pinion.
14. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Using SST, remove the front tapered roller bearing (outer) from the differential carrier.
(b) Using a brass bar and a hammer, remove the oil storage ring from the carrier.
15. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using a brass bar and a hammer, remove the rear tapered roller bearing (outer) from the carrier.
16. REMOVE DIFFERENTIAL RING GEAR

(a) Place matchmarks on the ring gear and differential case.
(b) Using a screwdriver and a hammer, unstake the 5 lock plates.
(c) Remove the 10 ring gear set bolts and 5 lock plates.

(d) Using a plastic hammer, tap on the ring gear to separate it from the differential case.
17. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT
HINT: It will be done only when it exceeds the limit at the ring gear runout check.

(a) Install the rear differential case bearing to the differential case.
(b) Install the differential case to the differential carrier.
(c) Install the 2 bearing caps with the 4 bolts to the differential carrier.
Torque: 85 Nm (867 kgf-cm, 63 ft-lbf)
(d) Inspect the differential case runout.
Maximum runout:
0.07 mm (0.0028 in.)
(e) Remove the differential case.
(f) Remove the rear differential case bearing.
18. REMOVE REAR DIFFERENTIAL CASE BEARING

(a) Using SST, remove the 2 rear differential case bearings from the differential case assembly.
SST: 09950-40011
09951-04020
09952-04010
09953-04030
09954-04010
09955-04061
09957-04010
09958-04011
SST: 09950-60010
09951-00360
HINT: Fix the claws of SST to the notches in the differential case assembly.

19. DISASSEMBLE DIFFERENTIAL CASE

(a) Place matchmarks on the LH and RH cases.
(b) Remove the 8 bolts.

(d) Remove these parts from the differential case.

20. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
(a) Check that there is no damage to the differential pinion and differential side gear.
If the differential pinion and/or differential side gear is damaged, replace the differential.