Disassembly

DISASSEMBLY





1. CHECK RUNOUT OF COMPANION FLANGE
Using a dial indicator, measure the vertical and lateral runout of the companion flange.
Maximum runout:
Vertical runout: 0.10 mm (0.0039 inch)
Lateral runout: 0.10 mm (0.0039 inch)
If the runout is not within the specification, replace the companion flange.





2. CHECK RING GEAR RUNOUT
Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.07 mm (0.0028 inch)
If the runout is not within the specification, replace the ring gear.





3. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

HINT: Before measurement, rotate the ring gear 5 times or more.





4. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.
Preload (at starting): 0.5 - 0.8 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
5. CHECK TOTAL PRELOAD
Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting): Drive pinion preload plus 0.4 - 0.6 Nm (4 - 6 kgf-cm, 3.5 - 5.2 inch lbs.)
If necessary, disassemble and inspect the differential.
6. CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION





7. w/DIFF. LOCK: REMOVE ACTUATOR
a. Remove the bolt and actuator from the differential carrier.
b. Remove the O-ring.





8. w/DIFF. LOCK: REMOVE INDICATOR SWITCH
Remove the indicator switch and gasket.
9. w/DIFF. LOCK: REMOVE SHIFT FORK SHAFT
a. Using a hexagon wrench, remove the 2 straight screw plugs.





b. Remove the spring seat, compression spring and ball.





c. Using a pin punch and hammer, remove the slotted spring pin.
d. Remove the 2 bolts from the shaft retainer.





e. Using a plastic hammer, remove the shaft retainer.
f. Remove the shift fork shaft.

HINT: Pull out the shift fork shaft with a screwdriver turned round.

10. REMOVE COMPANION FLANGE
a. Using a chisel and hammer, unstake the nut.





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





c. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)





11. REMOVE OIL SEAL AND OIL SLINGER
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
b. Remove the oil slinger.





12. REMOVE FRONT BEARING
Using SST, remove the front bearing from the drive pinion.
SST 09556-22010





13. w/o Diff. lock: REMOVE DIFFERENTIAL CASE
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 2 adjusting nut locks.
c. Remove the 4 bolts and 2 bearing caps.
d. Remove the 2 adjusting nuts.
e. Remove the differential case with the side bearing outer races from the differential carrier.

HINT: Tag the disassembled parts to show the location for reassembly.

14. w/Diff. lock: REMOVE DIFFERENTIAL CASE





a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 2 adjusting nut locks.
c. Remove the 4 bolts and 2 bearing caps.





d. Remove the differential case with side bearing outer races, adjusting nut and sleeve from the differential carrier.
e. Remove the shift fork.
15. REMOVE DRIVE PINION AND BEARING SPACER
a. Remove the drive pinion with the rear bearing.
b. Remove the bearing spacer.





16. REMOVE DRIVE PINION REAR BEARING
a. Using SST and a press, remove the bearing from the drive pinion.
SST 09950-00020

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

b. Remove the plate washer from the drive pinion.





17. REMOVE FRONT AND REAR BEARING OUTER RACES AND OIL STORAGE RING
a. Using SST, remove the front bearing outer race.
SST 09308-00010
b. Using a brass bar and hammer, remove the oil storage ring.
c. Using a brass bar and hammer, remove the rear bearing outer race.





18. REMOVE RING GEAR
a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver and 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.





19. w/o Diff. lock: CHECK DIFFERENTIAL CASE RUNOUT
a. Place the bearing outer races on their respective bearings. Check that the left and right outer races are not interchanged.
b. Install the differential case in the differential carrier.
c. When there is no play left in the side bearings, install the plate washers.
d. Align the matchmarks on the bearing cap and differential carrier.
e. Install and uniformly tighten the 4 bearing cap bolts in several passes.
f. Using a dial indicator, measure the differential case runout.
Maximum runout: 0.07 mm (0.0028 inch)
g. Remove the differential case.





20. w/Diff. lock: CHECK DIFFERENTIAL CASE RUNOUT
a. Install the differential case in the differential carrier and tighten the adjusting nut just to where there is no play in the bearing.
b. Using a dial indicator, measure the differential case runout.
Maximum runout: 0.07 mm (0.0028 inch)
c. Remove the differential case.





21. REMOVE SIDE BEARINGS FROM DIFFERENTIAL CASE
Using SST, remove the side bearings from the differential case.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010, (09951-00480), 09950-60020, (09951-00730)

HINT: Fix the claws of SST to the notches in the differential case.





22. DISASSEMBLE DIFFERENTIAL CASE
a. Place matchmarks on the LH and RH cases.
b. Remove the 8 bolts uniformly, a little at a time.
c. Using a plastic hammer, separate the LH and RH cases.
d. Remove the 2 side gears, 2 side gear thrust washers, spider, 4 pinion gears and 4 pinion gear thrust washers.





23. w/DIFF. LOCK: INSPECT SLEEVE
a. Install the sleeve to the differential case (LH) and check that it moves smoothly.
b. Install the sleeve to the side gear and check it moves smoothly.





24. w/DIFF. LOCK: MEASURE CLEARANCE OF SHIFT FORK AND SLEEVE
Using a feeler gauge, measure the clearance between the shift fork and sleeve.
Clearance (Reference): 0.15 - 0.35 mm (0.006 - 0.014 inch)

REPLACEMENT
1. REPLACE COMPANION FLANGE DUST DEFLECTOR





a. Using SST and a press, remove the dust deflector.
SST 09950-00020





b. Using SST and a press, install a new dust deflector.
SST 09726-40010