Part 1

Part 1:

Part 2:

COMPONENTS

DISASSEMBLY OF DIFFERENTIAL




1. REMOVE CARRIER COVER




2. MEASURE TOTAL PRELOAD
Using a torque meter, measure the total preload, and make a note of it.




3. MEASURE BACKLASH OF SIDE GEAR
Measure each side gear backlash while holding one pinion toward the case.

Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)




4. REMOVE LH BEARING RETAINER
a. Remove the six bolts or five bolts.
b. Tap the retainer with a plastic hammer to remove it.
c. Remove the O-ring from the retainer.

5. REMOVE DIFFERENTIAL CASE




a. Remove the two bolts and side bearing cap.




b. Remove the differential case, outer race and adjusting shim from the case.




6. MEASURE DRIVE PINION PRELOAD
Using a torque meter, measure the drive pinion preload.

Preload (at starting): Reused bearing 5 - 8 kg-cm (4.3 - 6.9 in.lb, 0.5 - 0.8 N.m)

The total preload measured in step 2, minus the drive pinion preload, equals 1.5 - 2.0 kg-cm (1.3 - 1.7 in.lb, 0.1 - 0.2 N.m). If the result is not within this specification, the side bearing preload is wrong.




7. REMOVE DRIVE PINION CAP
Remove the bolt and pull out the drive pinion cap.

8. REMOVE COUNTER DRIVEN GEAR




a. Using a chisel, loosen the staked part of the nut.




b. Using SST to hold the gear, remove the nut.
SST 09330 - 00021, 09350 - 32014 (09351 - 32032)




c. Using SST, remove the gear and bearing.
SST 09350 - 32014 (09351 - 32061)




9. REMOVE OUTER RACE, OIL SLINGER AND SPACER
a. Using SST, remove the outer race.
SST 09350 - 32014 (09308 - 10010)
b. Remove the oil slinger and spacer.

10. REMOVE DRIVE PINION




a. Using SST, remove the snap ring.
SST 09350 - 32014 (09351 - 32050)




b. Insert the brass bar into the case hole to tap out the drive pinion.




c. Remove the drive pinion.




d. Remove the O-ring from the cage.

DISASSEMBLY OF DIFFERENTIAL CASE

1. REMOVE RING GEAR




a. Loosen the staked part of the lock plate.




b. Remove the eight bolts and locking plates.
c. Using a copper hammer, tap on the ring gear to remove it from the case.




2. REMOVE SIDE BEARINGS
Fasten SST under the bearing above the cut-outs on the speedometer drive gear. Remove the bearing from the case.
SST 09502 - 10012




3. CHECK SIDE GEAR BACKLASH
Using a dial gauge, measure the backlash of one side gear while holding one pinion toward the case.

Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)

4. DISASSEMBLE DIFFERENTIAL CASE




a. Drive out the pinion shaft lock pin from the side on which the ring gear is installed.




b. Remove the pinion shaft from the case.
c. Remove the two pinions and two side gears with the four thrust washers.




5. REMOVE LH OIL SEAL
Using a hammer and screwdriver remove the oil seal.




6. REMOVE BEARING OUTER RACE FROM LH SIDE BEARING RETAINER
Using SST, press out the outer race and shim.
SST 09350 - 32014 (09351 - 32090)




7. REMOVE RH OIL SEAL
Using a hammer and screwdriver, remove the oil seal.

ASSEMBLY OF DIFFERENTIAL CASE




1. INSTALL RH OIL SEAL
a. Using SST, drive in a new oil seal until its surface is flush with the surface of the case.
SST 09350 - 32014 (09351 - 32130, 09351 - 32150)
b. Coat the oil seal lip with MP grease.




2. INSTALL BEARING OUTER RACE TO LH SIDE BEARING RETAINER
a. Place the shim onto the retainer.

NOTE: Use either the shim which was removed or one

2. 10 mm (0.0827 in.) thick.
b. Using SST, press a new outer race into the retainer.
SST 09350 - 32014 (09351 - 32111)




3. INSTALL LH OIL SEAL
a. Using SST, drive in a new oil seal.
SST 09350 - 32014 (09351 - 32130, 09351 - 32150)

Oil seal drive in depth: 0 mm (0 in.)

b. Coat the oil seal lip with MP grease.

4. ASSEMBLE DIFFERENTIAL CASE




a. Install the removed thrust washers to the side gears.




b. Install the side gears with thrust washers, pinion thrust washers and pinion gears.




c. Install the pinion shaft.




d. Check the side gear backlash.
Measure the side gear backlash while holding one pinion gear toward the case.

Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)




Refering to the table, select thrust washers which will ensure that the backlash is within specification. Try to select washers of the same size for both sides.
If the backlash is not within specification, install a thrust washer of a different thickness.




e. Using a hammer and punch, drive the lock pin through the case and hole in the pinion shaft.
f. Stake the differential case.

5. INSTALL SIDE BEARINGS




a. Install the speedometer drive gear onto the differential case.




b. Using SST and a press, press each side bearing onto the differential case.
SST 09350 - 32014 (09351 - 32090, 09351 - 321 20)

6. INSTALL RING GEAR




a. Clean the contact surface of the differential case.
b. Heat the ring gear to about 100 °C (212 °F) in an oil bath.

CAUTION: Do not heat the ring gear above 110 °C (230 °F).

c. Clean the contact surface of the ring gear with cleaning solvent.




d. Quickly install the ring gear on the differential case.
e. Install a new locking plates and set bolts. Tighten the set bolts uniformly and a little at a time. Torque the bolts.

Torque: 985 kg-cm (71 ft-lb, 97 N.m)




f. Using a hammer and drift punch, stake the locking plates.

NOTE: Stake one claw flush with the flat surface of the nut. For the claw contacting the protruding portion of the nut, stake only the half on the tightening side.

DISASSEMBLY OF DRIVE PINION




1. REMOVE GOVERNOR DRIVE GEAR
Using a shop press, press out the rotor sensor or governor drive gear.




2. REMOVE BEARING CAGE FROM DRIVE PINION




3. REMOVE DRIVE PINION SHAFT BEARING
Using SST, press out the bearing. SST 09950 - 00020




4. REMOVE SHAFT BEARING OUTER RACE FROM CAGE
Using a hammer and brass bar, drive out the outer race from the cage.




5. REMOVE OIL SEALS FROM CAGE
Using SST, press out the two oil seals together.
SST 09350 - 32014 (09351 - 32090)




6. REMOVE COUNTER DRIVEN GEAR BEARING
Using SST, press out the bearing.
SST 09950 - 00020