Part 1
DIFFERENTIAL CARRIER ASSEMBLY REAR (4WD)OVERHAUL
HINT:
^ Differential components
^ Rear drive shaft components
1. REMOVE REAR WHEEL
2. REMOVE EXHAUST PIPE ASSEMBLY
3. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
SST 09325-20010
4. REMOVE REAR DIFFERENTIAL FILLER PLUG
a. Using a hexagon wrench (10 mm), remove the filler plug and gasket.
5. REMOVE REAR DIFFERENTIAL DRAIN PLUG
a. Using a hexagon wrench (10 mm), remove the drain plug and gasket, drain the oil.
6. REMOVE SPEED SENSOR REAR LH
7. REMOVE SPEED SENSOR REAR RH
HINT: Removal procedure of RH side is the same as that of LH side.
8. REMOVE REAR AXLE SHAFT LH NUT
SST 09930-00010
9. REMOVE REAR AXLE SHAFT RH NUT
SST 09930-00010
HINT: Removal procedure of RH side is the same as that of LH side.
10. REMOVE REAR DRIVE SHAFT ASSEMBLY LH
11. REMOVE REAR DRIVE SHAFT ASSEMBLY RH
HINT: Removal procedure of RH side is the same as that of LH side.
12. REMOVE DIFFERENTIAL CARRIER ASSEMBLY REAR
a. Support the differential carrier assembly rear with a jack.
b. Remove the bolt and nut, separate the rear differential support No.1.
c. Remove the 2 bolts, separate the differential support assembly rear.
NOTICE: Be careful not to drop the differential carrier assembly rear.
13. REMOVE DIFFERENTIAL SUPPORT ASSEMBLY REAR
a. Remove the 3 bolts and differential support assembly rear.
14. REMOVE REAR DIFFERENTIAL DYNAMIC DAMPER
a. Remove the 2 bolts and rear differential dynamic damper from the rear differential support No.1.
15. REMOVE REAR DIFFERENTIAL SUPPORT NO.1
a. Remove the 2 bolts, 2 nuts and rear differential support No.1.
16. 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.
d. Remove the bolt and oil deflector from the carrier cover.
17. FIX DIFFERENTIAL CARRIER ASSEMBLY REAR
18. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
a. Using a dial indicator, check the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
If the runout is greater than the maximum, replace the ring gear with a new one.
19. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using a dial indicator, check the backlash of the ring gear.
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.
20. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See step 60)
21. DIFFERENTIAL PINION AND SIDE GEAR BACKLASH
a. Using a dial indicator, check the backlash of the side gear while holding 1 pinion gear toward the differential case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specification, install the 2 side gear thrust washers of different thickness (See step 48).
HINT: Measure the backlash of the side gear with the side gear shaft installed.
22. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
a. Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
Maximum runout: 0.10 mm (0.0039 inch)
23. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the back lash between the drive pinion and ring gear.
Preload (at starting): 0.6 - 0.9 Nm (6 - 9 kgf-cm, 5.2 - 7.8 inch lbs.)
24. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the total preload.
Total preload (at starting): Drive pinion preload plus 0.3 - 0.5 Nm (3 - 5 kgf-cm, 2.6 - 4.3 inch lbs.)
Disassemble and inspect the differential as necessary.
25. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY
a. Using needle nose pliers, remove the 2 snap rings from the 2 side gear shafts.
b. Remove the 2 side gear shafts.
26. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT DUST COVER
a. Using a screwdriver and a hammer, remove the side gear shaft dust cover.
27. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL
a. Using SST, remove the 2 oil seals from the housing.
SST 09308-00010
28. REMOVE REAR DRIVE PINION NUT
a. Using a chisel and a hammer, unstake the staked part of the nut.
SST 09930-00010
b. Using SST to hold the flange, remove the nut.
SST 09330-00021
29. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
a. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
30. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, remove the dust deflector.
SST 09950-60010 (09951-00360), 09950-70010 (09951-07150), 09950-00020
31. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
32. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
33. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST, remove the front bearing from the drive pinion.
SST 09556-22010