Disassembly

DIFFERENTIAL: REAR DIFFERENTIAL CARRIER: DISASSEMBLY

DISASSEMBLY

1. 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.
2. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY
3. 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 in.)
If the runout is greater than the maximum, replace the ring gear with a new one.
4. 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 in.)
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.
5. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Reassembly

6. INSPECT 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 in.)
If the backlash is not within the specification, install the 2 side gear thrust washers of differential thickness Reassembly.
HINT: Measure the backlash of the side gear with the side gear shaft installed.

7. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY






(a) Using a dial gauge, measure the runout of the companion flange vertically and horizontally.
Maximum runout:
0.10 mm (0.0039 in.)
8. 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 N*m (6 to 9 kgf*cm, 5.2 to 7.8 in.*lbf)
9. 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 N*m (3 to 5 kgf*cm, 2.6 to 4.3 in.*lbf)
Disassemble and inspect the differential as necessary.
10. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL






(a) Using SST(s), remove the 2 oil seal from the housing.
SST: 09308-00010
11. 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
12. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY






(a) Using SST(s), remove the companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03020
13. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR






(a) Using SST(s) and a press, remove the dust deflector.
SST: 09950-60010
09951-00360
SST: 09950-70010
09951-07150
SST: 09950-00020
14. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL






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






(a) Using SST(s), remove the front bearing from the drive pinion.
SST: 09556-22010
17. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
18. REMOVE DIFFERENTIAL CASE ASSEMBLY






(a) Align matchmarks on the bearing cap and differential carrier.
(b) Remove the 4bolts 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 races to show the location for reassembly.

19. REMOVE DIFFERENTIAL DRIVE PINION
(a) Remove the differential drive pinion.
20. 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.
21. 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.
22. 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.
23. 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.
24. INSPECT 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-lbf)
(c) Using a dial gauge, measure the differential case runout.
Maximum case runout:
0.07 mm (0.0028 in.)
(d) Remove the differential case.
25. REMOVE REAR DIFFERENTIAL CASE BEARING






(a) Using SST(s), remove the case bearing (LH) from the differential case.
SST: 09950-40011
09951-00240
09951-04020
09952-04010
09953-04030
09954-04010
09955-04061
09957-04010
09958-04011
SST: 09950-60010
09951-00360
26. 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
SST: 09950-60010
09951-00360
27. 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)