INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE REAR SUB-ASSEMBLY

INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

INSPECT DIFFERENTIAL RING GEAR BACKLASH

REMOVE NO. 1 TRANSFER INDICATOR SWITCH

REMOVE REAR DIFFERENTIAL LOCK COVER

REMOVE DIFFERENTIAL LOCK SHIFT ACTUATOR

REMOVE DRIVE PINION COMPANION FLANGE REAR NUT

REMOVE REAR DRIVE PINION COMPANION FLANGE REAR SUB-ASSEMBLY

REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

REMOVE DIFFERENTIAL DRIVE PINION

REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

REMOVE DIFFERENTIAL RING GEAR

INSPECT RUNOUT OF DIFFERENTIAL CASE

DISASSEMBLE DIFFERENTIAL CASE

REMOVE REAR DIFFERENTIAL CASE BEARING

REMOVE REAR DIFFERENTIAL CASE BEARING

Using a dial indicator, measure the vertical and lateral runout of the companion flange.

• Maximum Runout:

• Runout	Specified Condition
  Vertical runout	0.10 mm (0.00394 in.)
  Lateral runout	0.10 mm (0.00394 in.)

If the runout is more than the maximum, replace the companion flange.

Using a dial indicator, measure the runout of the ring gear.

• Maximum runout:
• 0.05 mm (0.00197 in.)

If the runout is more than the maximum, replace the ring gear with a new one.

Using a dial indicator, measure the backlash of the ring gear.

• Standard backlash:
• 0.10 to 0.20 mm (0.00394 to 0.00787 in.)

• HINT:

• Measure at 3 or more positions around the circumference of the ring gear.

If the backlash is not as specified, adjust the side bearing preload or repair as necessary.

Remove the switch and gasket.

Remove the 3 bolts.

Using a brass bar and hammer, tap on the cover to remove it.

Remove the 4 bolts.

Remove the shift fork shaft bolt.

Using a screwdriver, pull out the actuator and remove the sleeve and shift fork.

Using SST and a hammer, unstake the nut.

• SST
• 09930-00010

Using SST to hold the companion flange, remove the nut.

• SST
• 09330-00021(09330-00030)

Using SST, remove the companion flange.

• SST
• 09950-30012(09951-03010,09953-03010,09954-03010,09956-03030)

Using SST, remove the oil seal.

• SST
• 09308-10010

Using SST, remove the bearing (inner race).

• SST
• 09556-22010

If the front bearing is damaged or worn, replace the bearing.

Place matchmarks on the bearing caps and differential carrier.

Remove the 4 bolts and 2 bearing caps.

Using SST and a hammer, remove the plate washers.

• SST
• 09504-22011

• HINT:

• Measure the thickness of each plate washer and note it down.

Remove the differential case with the side bearing (outer race) from the differential carrier.

• HINT:

• Tag the bearing outer races to show the location for reassembly.

Using SST and a press, press out the rear bearing (inner race) from the drive pinion.

• SST
• 09950-00020

If the drive pinion or ring gear is damaged, replaced them as a set.

Using a brass bar and hammer, tap out the bearing (outer race).

Using a brass bar and hammer, tap out the bearing (outer race).

Place matchmarks on the ring gear and differential case.

Remove the 12 ring gear set bolts.

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

Place the bearing outer races on their respective bearings.

• HINT:

• Do not interchange the left and right outer races.

Install the assembled plate washers to the side bearing.

Install the differential case to the differential carrier.

• HINT:

• If it is difficult to install the differential case to the carrier, replace the plate washer with a thinner one.

However, select a plate washer that allows no clearance between it and the carrier.

Align the matchmarks on the bearing caps and differential carrier.

Install and uniformly tighten the 4 bolts a little at a time.

Using a dial indicator, measure the differential case runout.

• Maximum case runout:
• 0.04 mm (0.00157 in.)

If the runout is more than the maximum, replace the differential case and side bearings as a set.

Remove the differential case.

Place matchmarks on the differential case and differential cover.

Using a T10 "TORX" socket, remove the 5 set bolts and 3 pinion shaft pins.

Separate the cover and case.

Remove the 2 side gears, 2 side gear thrust washers, 4 pinion gears, 4 pinion gear thrust washers, 3 pinion shafts and holder from the differential case.

Using SST, remove the side bearing.

• SST
• 09950-40011(09952-04010,09953-04020,09954-04010,09955-04061)

• HINT:

• Fix the claws of SST to the notches in the differential case.

Using SST, 4 bolts and a press, remove the bearing.

• SST
• 09950-60010(09951-00580)
  09950-70010(09951-07150)