Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

Using a dial indicator, measure the runout of the companion flange vertically and laterally.

Maximum runout:

Runout	Specified Condition
Vertical runout	0.10 mm (0.0039 in.)
Lateral runout	0.10 mm (0.0039 in.)

1. If the runout is greater than the maximum, replace the companion flange.
   

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

Maximum runout:

0.07 mm (0.0028 in.)

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

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

Standard backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

1. If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.
   

   HINT:

   Perform the measurements at 3 or more positions around the side bearing preload.

Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.

Standard preload (at start of torque):

0.56 to 0.85 N*m (6 to 9 kgf*cm, 4.9 to 7.5 in.*lbf)

1. If necessary, disassemble and inspect the differential.
   

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

Using a torque wrench, measure the total preload.

Standard total preload:

0.39 to 0.59 N*m (4 to 6 kgf*cm, 3.4 to 5.2 in.*lbf) + drive pinion preload

1. If necessary, disassemble and inspect the differential.
   

Remove the 4 bolts and actuator from the differential carrier.

Remove the O-ring.

Remove the switch and gasket.

Using a 6 mm hexagon wrench, remove the 2 screw plugs.

Remove the spring seat, spring and steel ball.

Using a 5 mm pin punch and hammer, tap out the slotted spring pin from the shift fork shaft.

Remove the 2 bolts from the shaft retainer.

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

Remove the shift fork shaft.

Using SST and a hammer, loosen the staked part of the nut.

SST

09930-00010(09931-00010,09931-00020)

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

SST

09330-00021(09330-00030)

Using SST, remove the companion flange.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03030,09956-03040)

NOTICE:

Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

Using SST and a press, press out the dust deflector.

SST

09950-60010(09951-00380)
09950-70010(09951-07150)
09950-00020

NOTICE:

Do not drop the companion flange.

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

SST

09308-10010

Using SST, remove the roller bearing (inner) from the drive pinion.

SST

09556-22010

Remove the 2 bolts and 2 adjusting locks.

Place matchmarks on the bearing cap and differential carrier.

Remove the 4 bolts and 2 differential bearing caps.

Remove the 2 adjusting nuts.

Remove the rear differential case assembly from the differential carrier.

HINT:

Tag the 2 case bearing outer races to show the location for reassembly.

Remove the drive pinion and bearing spacer from the differential carrier.

Using SST and a press, press out the roller bearing (inner) 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.

Using SST, remove the roller bearing (outer) from the carrier.

SST

09308-00010

Using a brass bar and hammer, tap out the oil storage ring from the carrier.

HINT:

If the bearing is damaged during removal, replace it.

Using a brass bar and hammer, tap out the rear tapered roller bearing (outer) from the carrier.

HINT:

If the bearing is damaged during removal, replace it.

Place matchmarks on the ring gear and differential case.

Using a screwdriver and hammer, pry out the lock plates.

Remove the 10 ring gear set bolts and 5 lock plates.

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

Install the rear differential case bearing to the differential case.

Install the differential case to the differential carrier.

Install the 2 bearing caps to the differential carrier with the 4 bolts.

Torque:

85 N*m{867 kgf*cm, 63 ft.*lbf}

Using dial indicator, measure the differential case runout.

Maximum runout:

0.07 mm (0.0028 in.)

Remove the differential case.

Remove the rear differential case bearing.

Using SST, remove the 2 bearings from the differential case.

SST

09950-40011(09951-04020,09952-04010,09953-04030,09954-04010,09955-04061,09957-04010,09958-04011)
09950-60010(09951-00360)

HINT:

Do not remove the case bearing when not replacing the differential case.

Place matchmarks on the LH and RH cases.

Remove the 8 bolts uniformly, a little at a time.

Using a plastic-faced hammer, tap out the LH case from the RH case.

Remove the following parts from the differential cases.

1. (1) Side gear (2 pieces)
   
2. (2) Side gear thrust washer (2 pieces)
   
3. (3) Spider
   
4. (4) Pinion gear (4 pieces)
   
5. (5) Pinion gear thrust washers (4 pieces)
   

Install the sleeve to the differential case LH and check that it moves smoothly.

Install the sleeve to the side gear and check that it moves smoothly.

Using a feeler gauge, measure the clearance between the shift fork and sleeve.

Standard clearance (reference):

0.15 to 0.35 mm (0.006 to 0.014 in.)

Check that the differential pinion and differential side gear are not worn.

1. If the differential pinion or differential side gear is worn, replace the differential.
   

Check that the differential case is not damaged.

1. If the differential case is damaged, replace it.