REMOVE REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG

REMOVE REAR DIFFERENTIAL CARRIER COVER

REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

SECURE REAR DIFFERENTIAL CARRIER

INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

INSPECT DIFFERENTIAL RING GEAR BACKLASH

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION

INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

INSPECT TOTAL PRELOAD

REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

REMOVE REAR DIFFERENTIAL CASE BEARING

REMOVE REAR DIFFERENTIAL CASE BEARING

REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

REMOVE REAR DRIVE PINION NUT

REMOVE REAR DRIVE PINION COMPANION FLANGE

REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

REMOVE DIFFERENTIAL DRIVE PINION

REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

REMOVE DIFFERENTIAL RING GEAR

INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY

REMOVE REAR DIFFERENTIAL CASE BEARING

INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

Remove the breather plug from the differential carrier cover.

Remove the 8 bolts from the differential carrier cover.

Using a brass bar and a hammer, remove the differential carrier cover from the differential carrier.

• NOTICE:

Remove the bolt and oil deflector from the differential carrier cover.

Set the differential carrier to the overhaul stand, etc., as shown in the illustration.

Set the dial indicator perpendicular to the end of the ring gear face.

Rotate the ring gear and measure the backlash.

• Maximum runout:
• 0.05 mm (0.0020 in.)

If the runout exceeds the specified maximum value, remove the ring gear and check the runout of the differential case.

While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

• Backlash:
• 0.08 to 0.13 mm (0.0031 to 0.0051 in.)

If the backlash is not within the specified range, adjust the backlash or repair as necessary.

Coat 3 or 4 teeth at the 3 different positions on the ring gear with Prussian blue.

Rotate the ring gear in both directions.

Inspect the tooth contact pattern.

If the teeth are not contacting properly, use the following table to select a proper plate washer for correction.

• HINT:

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 not, replace the rear differential case sub-assembly with a new one.

Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 in.) away from the end of the shaft.

• Maximum runout:
• 0.08 mm (0.0031 in.)

If the runout is greater than the maximum, replace the drive pinion and ring gear.

Using SST and a torque wrench, measure the starting torque of the drive pinion. The backlash between the drive pinion and ring gear should allow enough movement of the drive pinion to allow this measurement to be performed. Make sure not to include the preload of the ring gear (differential case) in the measurement of the drive pinion preload.

• SST
• 09229-55010

• Drive pinion preload (at starting):

• Specifications	Preload
  New bearing	1.22 to 1.80 N*m (12.4 to 18.4 kgf*cm, 10.8 to 15.9 in.*lbf)
  Reused bearing	0.50 to 0.80 N*m (5.1 to 8.2 kgf*cm, 4.3 to 6.9 in.*lbf)

If the preload is not within the specified range, adjust the rear differential drive pinion preload or repair as necessary.

Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

• SST
• 09229-55010

• Total preload (at starting):

• Grade: luxury

  Specifications	Preload
  New bearing	1.92 to 3.89 N*m (19.6 to 39.7 kgf*cm, 17.0 to 34.4 in.*lbf)
  Reused bearing	1.20 to 2.89 N*m (12.2 to 29.5 kgf*cm, 10.6 to 25.6 in.*lbf)

• Grade: sport

  Specifications	Preload
  New bearing	1.75 to 3.38 N*m (17.8 to 34.5 kgf*cm, 15.5 to 29.9 in.*lbf)
  Reused bearing	1.03 to 2.38 N*m (10.5 to 24.3 kgf*cm, 9.1 to 21.1 in.*lbf)

If the preload is not within the specified range, adjust the total preload or repair as necessary.

Using SST, remove the 2 oil seals.

• SST
• 09308-00010

Install SST to the differential carrier.

• SST
• 09571-50010

Tighten the SST bolt (A) until the SST disc slightly touches the case bearing outer race.

Install a dial indicator to the rear differential carrier.

Tighten the SST bolt. Push in the differential case bearing (outer race) until an approximately 0.1 mm (0.004 in.) clearance is created between the bearing (outer race) and the differential side gear shaft snap ring.

• NOTICE:

• Observe the dial indicator and ensure that the bearing (outer race) is not pushed in more than 0.2 mm (0.008 in.).

• HINT:

Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.

• HINT:

• For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result.

Remove the dial indicator and loosen the SST bolt.

• NOTICE:

• Do not remove the SST.

Using SST and a hammer, create a clearance between the case bearing outer race on the back surface of the ring gear and side gear shaft snap ring.

• SST
• 09608-32010
  09950-70010(09951-07200)

• HINT:

• The clearance is not visible, but tapping the SST with a hammer three or four times should create sufficient clearance.

Using snap ring pliers, remove the side gear shaft snap ring on the back surface of the ring gear.

• HINT:

• For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result.

Tighten the SST bolt and push out the case bearing outer race on the back surface of the ring gear.

• SST
• 09571-50010

• NOTICE:

• Do not drop the case bearing outer race.

Remove the SST.

Raise the ring gear of the differential case slightly to remove the ring gear tooth side case bearing outer race.

• HINT:

• For reassembly, check the installation position of the case bearing outer race and the side gear shaft snap ring before removing the case bearing outer race. Write down the result.

Remove the rear differential case assembly.

• NOTICE:

• Do not damage the case bearing.

Using SST and a hammer, unstake the staked part of the drive pinion nut.

• SST
• 09930-00010

• NOTICE:

Using SST to hold the flange, remove the drive pinion nut.

• SST
• 09229-55010
  09330-00021
  09950-30012(09955-03040)

Using SST, remove the companion flange.

• SST
• 09950-30012(09951-03010,09953-03010,09954-03010,09955-03040,09956-03060)

• NOTICE:

• Apply grease to the threads and tip of the SST center bolt before use.

Using SST and a press, remove the dust deflector.

• SST
• 09950-60010(09951-00440)
  09950-00020
  09950-70010(09951-07100)

Using SST, remove the oil seal from the differential carrier.

• SST
• 09308-00010

Remove the drive pinion oil slinger.

Using a press, remove the drive pinion from the differential carrier.

• NOTICE:

• Do not drop the drive pinion.

Remove the drive pinion spacer.

Remove the rear drive pinion front tapered roller bearing inner race from the differential carrier.

Using a brass bar and a hammer, remove the rear drive pinion front tapered roller bearing outer race from the differential carrier.

Using SST and a press, remove the rear drive pinion rear tapered roller bearing inner race from the drive pinion.

• SST
• 09950-00020

• HINT:

• If either the drive pinion or ring gear is damaged, replace both as a set.

Using a brass bar and a hammer, remove the rear drive pinion rear tapered roller bearing outer race from the differential carrier.

Remove the plate washer.

Put machmarks on the ring gear and differential case.

Remove the 10 ring gear set bolts.

Using a plastic hammer, tap on the ring gear to separate it from the differential case.

• NOTICE:

• Do not damage the ring gear.

Install the differential case to the differential carrier.

• NOTICE:

• Do not damage the case bearing.

Using SST and a hammer, install the case bearing outer race on the ring gear tooth side.

• SST
• 09608-32010
  09950-70010(09951-07200)

• HINT:

• Tap in the case bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.

Install SST to the differential carrier.

• SST
• 09571-50010

Tighten the SST bolt (A) until the SST disc slightly touches the case bearing outer race.

Using SST and a hammer, install the case bearing outer race on the ring gear back surface side.

• SST
• 09608-32010
  09950-70010(09951-07200)

• HINT:

• Tap in the case bearing outer race until it touches the case bearing inner race roller.

Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.

Place a dial indicator on the differential case flange surface at a right angle.

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 with a new one.

Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.

Tighten the SST bolt to push out the ring gear back surface side case bearing outer race.

• SST
• 09571-50010

• NOTICE:

• Do not drop the case bearing outer race.

Remove the SST.

Raise the ring gear side of the differential case slightly to remove the ring gear tooth side case bearing outer race.

Remove the differential case from the differential carrier.

• NOTICE:

• Do not damage the case bearing.

Using SST, remove the case bearing inner races LH and RH from the differential case.

• SST
• 09950-40011(09951-04020,09952-04010,09953-04030,09954-04010,09955-04061,09957-04010,09958-04011)
  09950-60010(09951-00350,09951-00480,09952-06010)

• NOTICE:

Hold the differential case in a vise between aluminum plates.

• NOTICE:

• Do not overtighten the vise.

Place a dial indicator on the tip of the side gear tooth at a right angle. Hold the pinion gear in the differential case and check that the backlash is 0 mm (0 in.).

If not, replace the rear differential case sub-assembly with a new one.