Part 1
REAR DIFFERENTIAL CARRIER ASSEMBLYCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
DISASSEMBLY
1. REMOVE REAR DIFFERENTIAL CARRIER COVER
(a) Remove the 8 bolts from the carrier cover.
(b) Using a brass bar and hammer, tap out the cover from carrier.
(c) If necessary, remove the breather plug from the differential carrier cover.
(d) Remove the bolt and oil deflector from the differential carrier cover.
2. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY
3. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
(a) Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.05 mm (0.0020 in.)
If the runout is greater than the maximum, replace the drive pinion, ring gear and differential case.
4. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Using a dial indicator, measure the backlash of the ring gear.
HINT: Perform the measurements at 3 or more positions around the side bearing preload.
Standard backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 in.)
NOTICE: The difference between the maximum and minimum measured values must be less than 0.05 mm (0.0020 in.).
If the backlash is not as specified, adjust the backlash.
5. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Coat 3 or 4 teeth at 3 different positions on the ring gear with prussian blue.
(b) Hold the companion flange firmly and rotate the ring gear in both directions.
(c) Inspect the tooth contact pattern.
If the tooth contact pattern is not correct, replace the adjusting washer installed on the front of the drive pinion rear bearing.
NOTICE: Make sure to always replace the adjusting washer with a new one.
HINT: Refer to the adjusting washer table.
HINT: Rear differential drive pinion plate washers are available in 42 sizes, each with a 0.01 mm (0.0004 in.) thickness difference.
Standard plate washer thickness:
6. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
(a) Using a vise, hold the differential case between 2 aluminum plates.
(b) Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0 mm (0 in.).
If the backlash is not within the specification, replace the rear differential case sub-assembly with a new one.
7. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION
(a) Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 in.) from the end of the shaft.
Maximum runout: 0.08 mm (0.0031 in.)
HINT: If the runout is greater than the maximum, replace the drive pinion and ring gear.
8. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using SST and a torque wrench, measure the preload of backlash between the drive pinion and ring gear.
SST 09229-55010
Standard preload (at starting): 0.5 to 0.8 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf)
HINT: If the preload is not within the specification, adjust the rear differential drive pinion preload or repair as necessary.
9. INSPECT TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
SST 09229-55010
Standard total preload: Standard drive pinion preload plus 0.46 to 1.37 N*m (4.69 to 13.97 kgf*cm, 4.07 to 12.13 in.*lbf)
If necessary, disassemble and inspect the differential.
10. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST, tap out the 2 oil seals.
SST 09308-00010
11. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING (for Except ring gear side position)
(a) Install SST to the rear differential carrier.
SST 09571-50010
(b) Install a dial indicator to the rear differential carrier.
(c) Tighten SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.004 in.) clearance between the side bearing (outer race) and side gear shaft shaft snap ring.
NOTICE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.0008 in.).
HINT:
^ Set the dial indicator to the rearmost position (upper side in the illustration) of the area where the side gear shaft oil seal is tapped in.
^ Approximately 0.1 mm (0.004 in.) of clearance between the side bearing (outer race) and the side gear shaft shaft snap ring is sufficient for the washer to move slightly.
(d) Using snap ring pliers, remove the snap ring on the drive pinion side.
HINT: For reassembly purposes, measure the thickness of the side gear shaft shaft snap ring. Write down the result.
(e) Remove the dial indicator and loosen the SST bolt.
NOTICE: Do not remove SST.
12. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING (for Ring gear side position)
(a) Using SST and a hammer, create a clearance between the side bearing (outer) on the ring gear and side gear shaft shaft snap ring.
SST 09608-32010, 09950-70010 (09951-07200)
HINT: The clearance cannot be seen, but tapping SST with a hammer 3 or 4 times should be enough.
(b) Using snap ring pliers, remove the snap ring on the ring gear side.
HINT: For reassembly purposes, measure the thickness of the side gear shaft shaft snap ring. Write down the result.
13. REMOVE REAR DIFFERENTIAL CASE BEARING (for Ring gear side position)
(a) Tighten the SST bolt and push out the outer race on the ring gear side.
SST 09571-50010
NOTICE: Do not drop the side bearing (outer race).
(b) Remove SST.
14. REMOVE REAR DIFFERENTIAL CASE BEARING (for Except ring gear side position)
(a) Raise the ring gear of the differential case slightly to remove the drive pinion side outer race.
HINT: For reassembly, check the installation position of the outer race and the side gear shaft shaft snap ring before removing the outer race. Write down the result.
15. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY
NOTICE: Be careful not to damage the case bearing.
16. REMOVE REAR DRIVE PINION NUT
(a) Using a chisel and hammer, loosen the staked part of the nut.
(b) Using SST to hold the drive pinion companion flange, remove the nut.
SST 09229-55010, 09950-30012 (09955-03040), 09330-00021 (09330-00030)
17. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060)
18. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
19. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
20. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Using a magnet hand, remove the differential drive pinion oil slinger.
21. REMOVE DIFFERENTIAL DRIVE PINION
(a) Using a press, press out the drive pinion with the rear bearing from the differential carrier.
NOTICE: Be careful not to drop the drive pinion.
22. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Remove the spacer from the drive pinion.
23. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Remove the front bearing from the differential carrier.
(b) Using a brass bar and hammer, tap out the front bearing outer race.
24. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST and a press, press out the rear bearing from the drive pinion.
SST 09950-00020
NOTICE: Do not drop the drive pinion.
HINT: If the drive pinion or ring gear is damaged, replace them as a set.
(b) Using a brass bar and hammer, tap out the rear bearing outer race.
(c) Remove the plate washer.
25. REMOVE DIFFERENTIAL RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 10 ring gear set bolts.
(c) Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.
26. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY
NOTICE: This inspection is not necessary if the ring gear runout is within specified value
Maximum runout: 0.05 mm (0.0020 in.)
(a) Install the differential case as shown in the illustration.
(b) Using SST and a hammer, tap in the outer race on the drive pinion side.
SST 09608-32010, 09950-70010 (09951-07200)
HINT: Tap in the outer race until half of the side gear shaft shaft snap ring groove of the differential carrier can be seen.
(c) Place SST on the differential carrier.
SST 09571-50010
(d) Tighten the SST bolt until the SST disc lightly touches the case bearing (outer race).
(e) Using SST and a hammer, tap in the outer race on the ring gear side.
SST 09608-32010, 09950-70010 (09951-07200)
HINT: Tap in the outer race until it touches the case bearing roller.
(f) Place a dial indicator on the differential case flange surface at a right angle.
(g) Using a dial indicator, measure the differential case runout.
Maximum runout: 0.05 mm (0.0020 in.)
If the runout is greater than the maximum, replace the rear differential case sub-assembly with a new one.
27. REMOVE REAR DIFFERENTIAL CASE BEARING (for Ring gear side position)
(a) Tighten the SST bolt to push out the ring gear side outer race.
SST 09571-50010
NOTICE: Do not drop the side bearing (outer race).
(b) Remove SST.
28. REMOVE REAR DIFFERENTIAL CASE BEARING (for Except ring gear side position)
(a) Raise the ring gear side of the differential case slightly to remove the drive pinion side outer race.
29. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY
NOTICE: Be careful not to damage the side bearing.
30. REMOVE REAR DIFFERENTIAL CASE BEARING
(a) Using SST, remove the 2 differential case bearings from the differential case.
SST 09950-60010 (09951-00480), 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)
HINT: Do not remove the case bearing when not replacing the differential case.
NOTICE:
^ Do not deform the bearing case.
^ Hook the claws of SST to the bearing inner race of the differential case.
31. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
(a) Using SST and a press, press out the dust deflector.
SST 09950-60010 (09951-00440), 09950-00020, 09950-70010 (09951-07100)
NOTICE: Do not drop the differential carrier.
32. INSPECT DIFFERENTIAL PINION GEAR BACKLASH
(a) Using a vise, hold the differential case between 2 aluminum plates.
(b) Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0 mm (0 in.).
If the backlash is not as specified, replace the rear differential case with a new one.