Rear Differential Carrier Assembly (W/ Differential Lock) Disassembly

Fix the rear differential carrier assembly to the overhaul attachment.

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

Distance from center to runout measurement point:

30 mm (1.18 in.)

Maximum Runout:

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

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

Maximum runout:

0.07 mm (0.00276 in.)

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

Standard backlash:

0.10 to 0.20 mm (0.00394 to 0.00787 in.)

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

Standard preload (at starting):

0.88 to 1.98 N*m (9.0 to 20.2 kgf*cm, 7.8 to 17.5 in.*lbf)

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 (at starting):

Drive pinion preload plus 0.20 to 0.40 N*m (2.0 to 4.1 kgf*cm, 1.8 to 3.5 in.*lbf)

Remove the 4 bolts and actuator from the differential carrier.

Remove the O-ring.

Remove the indicator switch and gasket.

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

Remove the spring seat, spring and ball.

Using a 5 mm pin punch and hammer, remove the slotted pin.

Remove the 2 bolts from the shaft retainer.

Using a plastic-faced hammer, remove the shaft retainer.

Remove the shift fork shaft.

Remove the rear differential lock sleeve.

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

SST

09930-00010

NOTICE:

1. Be sure to use SST with the tapered surface facing the shaft.
   
2. Do not grind the tip of SST with a grinder, etc.
   
3. Completely loosen the staked part of the nut when removing.
   
4. Do not damage the threads of the drive pinion.
   

Use SST to hold the drive pinion companion flange.

SST

09330-00021

Using a 30 mm socket wrench, remove the rear drive pinion nut.

Using SST, remove the drive pinion companion flange.

SST

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

NOTICE:

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

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

SST

09308-10010

Using SST, remove the drive pinion tapered roller bearing from the drive pinion.

SST

09556-22010

NOTICE:

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

Remove the 2 bolts and 2 rear differential bearing adjusting nut 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 sub-assembly and 2 case bearings from the differential carrier.

HINT:

Tag the 2 case bearing outer races so that they can be reinstalled in the correct locations.

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

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

SST

09950-00020

HINT:

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

NOTICE:

Do not drop the drive pinion.

Using a brass bar and hammer, remove the rear tapered roller bearing from the carrier.

HINT:

If the bearing is damaged during the removal, replace it.

Place matchmarks on the ring gear and differential case.

Using a screwdriver and hammer, unstake the lock plates.

Remove the 12 ring gear set bolts.

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

Using SST, remove the front tapered roller bearing from the carrier.

SST

09308-00010

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

HINT:

If the bearing is damaged during the removal, replace it.

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:

103 N*m{1049 kgf*cm, 76 ft.*lbf}

Inspect the differential case runout.

Maximum runout:

0.07 mm (0.00276 in.)

Remove the differential case.

Remove the rear differential case bearing.

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

SST

09950-40011(09953-04020,09951-04010,09952-04010,09954-04010,09955-04061,09957-04010,09958-04011)
09950-60010(09951-00500,09951-00650,09952-06010)

Place matchmarks on the LH and RH cases.

Remove the 8 bolts.

Using a plastic-faced hammer, separate the LH and RH cases.

Remove the parts shown in the illustration from the differential case.