REAR DIFFERENTIAL DISASSEMBLY

id031400146500

Special service tool (SST)

49 0107 680A   Engine stand		49 L027 0A2   Differential hanger set		49 T032 317   Weight
49 T032 316   Shaft		49 L027 004   Gear case remover		49 L027 006   Serrated socket
49 L027 007   Hex socket		49 H027 002   Bearing remover		49 0839 425C   Bearing puller set

Warning

•  The engine stand is equipped with a self-lock mechanism. However, if the rear differential is tilted, the self-lock mechanism could become inoperative. This could cause the rear differential to rotate accidentally, resulting in injury. Therefore, make sure that the rear differential is not tilted when it is on the engine stand. When turning the rear differential, grasp the rotation handle firmly.

1.  Disassemble in the order shown in the figure.

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1	Oil temperature sensor
2	Rear cover (See Rear Cover Disassembly Note.)
3	Rear differential component (See Rear Differential Component Disassembly Note.)
4	Adjustment shim
5	Spacer
6	Oil seal (coupling component)
7	Locknut (See Locknut Disassembly Note.)
8	Drive pinion (See Drive Pinion Disassembly Note.)
9	Collapsible spacer
10	Bearing inner race (front)
11	Bearing inner race (rear) (See Bearing Inner Race (Rear) Disassembly Note.)
12	Spacer
13	Bearing outer race (See Bearing Outer Race Disassembly Note.)
14	Differential carrier
15	Ring gear (See Ring Gear Disassembly Note.)
16	Pin
17	Pinion shaft
18	Pinion gear
19	Thrust washer
20	Side gear
21	Thrust washer
22	Side bearing (See Side Bearing Disassembly Note.)
23	Gear case
24	Oil seal (side gear)

Rear Cover Disassembly Note

1.  Install SST (49 L027 0A2) to SST (49 0107 680A).

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2.  Install the rear differential to the SSTs.

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3.  Remove the rear cover using an oil pan seal cutter.

Rear Differential Component Disassembly Note

1.  If the rear differential component cannot be removed by hand, use the SSTs.

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2.  Place left and right identification marks on the the adjustment shims, spacers, and side bearing outer races.

Locknut Disassembly Note

1.  Remove the locknut using the SSTs.

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Drive Pinion Disassembly Note

1.  Lightly tap the drive pinion with a copper hammer and remove it.

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Bearing Inner Race (Rear) Disassembly Note

1.  Remove the bearing inner race (rear) using the SST and a press.

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Bearing Outer Race Disassembly Note

1.  Set the brass bar to the 2 notches on the differential carrier and lightly tap the race end surfaces alternately and remove the outer race.

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Ring Gear Disassembly Note

1.  Secure the gear case in a vise and remove the bolts.

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2.  Lightly tap the area around the ring gear using a plastic hammer and remove it from the gear case.

Side Bearing Disassembly Note

Caution

•  Place left and right identification marks on the side bearings.

1.  Remove the side bearing from the gear case using the SST.

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