REAR DIFFERENTIAL DISASSEMBLY

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1.  Disassemble in the order indicated in the table.

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1	Oil seal (side gear) (See Oil Seal (Side Gear) Disassembly Note.)
2	Breather
3	Rear cover (See Rear Cover Disassembly Note.)
4	Baffle plate
5	Differential gear case component (See Differential Gear Case Component, Adjustment Shim, Spacer Disassembly Note.)
6	Adjustment shim (See Differential Gear Case Component, Adjustment Shim, Spacer Disassembly Note.)
7	Spacer (See Differential Gear Case Component, Adjustment Shim, Spacer Disassembly Note.)
8	Side bearing outer race
9	Ring gear (See Ring Gear Disassembly Note.)
10	Side bearing (See Side Bearing Disassembly Note.)
11	Spring pin (See Spring Pin Disassembly Note.)
12	Pinion shaft
13	Pinion gear
14	Washer
15	Side gear
16	Thrust washer
17	Gear case
18	Locknut (See Locknut Disassembly Note.)
19	Washer
20	Companion flange (See Companion Flange Disassembly Note.)
21	Drive pinion component (See Drive Pinion Component Disassembly Note.)
22	Oil seal (companion flange) (See Oil Seal (Companion Flange) Disassembly Note.)
23	Spacer
24	Front bearing
25	Collapsible spacer
26	Rear bearing (See Rear Bearing Disassembly Note.)
27	Spacer
28	Drive pinion
29	Front bearing outer race (See Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note.)
30	Rear bearing outer race (See Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note.)
31	Differential carrier

Oil Seal (Side Gear) Disassembly Note

1.  Remove the oil seal using a tape-wrapped flathead screwdriver.

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Rear Cover Disassembly Note

Caution

•  Do not insert a flathead screwdriver between the contact surfaces of the differential carrier and the rear cover. Otherwise, the differential carrier and rear cover may be damaged.

1.  Remove the rear cover using a tape-wrapped flathead screwdriver.

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Differential Gear Case Component, Adjustment Shim, Spacer Disassembly Note

1.  Lightly tap the side bearing, adjustment shim, and spacer using a copper hammer to place the differential gear case component on the center of the differential carrier.

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Caution

•  Do not apply pressure of 2 t or more with the press. Otherwise, the part may become damaged.

•  For safety purposes, support the differential carrier using a wood block and level the end of the side bearing before performing the procedure.

2.  Remove the differential gear case component, adjustment shim, and spacer using the SSTs, a press, and a steel plate.

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Ring Gear Disassembly Note

1.  Secure the differential gear case component so that a clearance of approx. 10 mm {0.39 in} has been assured between the ring gear tooth surface and the upper end of the vise as shown in the figure.

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2.  Remove the ring gear securing bolts.

3.  Protect the ring gear tooth surface using a cloth.

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4.  Remove the ring gear by punching the ring gear in a criss-cross pattern from the bolt installation holes using a pin punch and a hammer.

Side Bearing Disassembly Note

1.  Remove the side bearing using the SST and a vise.

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Spring Pin Disassembly Note

1.  Tap the spring pin out from the direction shown in the figure using a round bar (diameter: 4 mm {0.2 in}, length: 80 mm {3.1 in}) and a hammer.

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Locknut Disassembly Note

1.  Secure the companion flange using the SST and remove the locknut.

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Companion Flange Disassembly Note

1.  Remove the companion flange using the SST and an adjustable wrench.

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Drive Pinion Component Disassembly Note

Caution

•  Perform the procedure by spreading a cloth on the drive pinion gear side. Otherwise, the drive pinion gear could be damaged.

1.  Install the removed locknut to the drive pinion top to prevent damage to the thread.

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2.  Remove the drive pinion component by tapping the locknut using a copper hammer.

3.  Remove the locknut installed in Step 1.

Oil Seal (Companion Flange) Disassembly Note

1.  Remove the oil seal using a tape-wrapped flathead screwdriver.

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Rear Bearing Disassembly Note

Caution

•  The drive pinion could be damaged if it falls off. Support the drive pinion with your hand when removing the rear bearing.

1.  Remove the rear bearing using the SST and a press.

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Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note

1.  Remove the bearing outer race by tapping the edge of the bearing outer race using a pin punch and a hammer.

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