Differential Carrier Assembly Disassembly

Fix the rear differential carrier in place with the overhaul attachment.

Remove the 4 stud bolts from the transmission coupling.

Using a 10 mm socket hexagon wrench, remove the rear differential drain plug and gasket.

Using a 10 mm socket hexagon wrench, remove the rear differential filler plug and gasket.

Using an 8 mm socket hexagon wrench, remove rear differential carrier cover plug.

Using a chisel and hammer, slightly lift up the rear differential carrier cover breather plug.

Using a screwdriver, lightly pry up and remove the rear differential carrier cover breather plug.

Install a dial gauge so that it is perpendicular to the inner side of the transmission coupling.

Using SST, rotate the transmission coupling assembly forward and backward and measure the vertical runout.

SST

09564-32011

Maximum vertical runout:

0.06 mm (0.00236 in.)

Install a dial gauge perpendicularly onto the transmission coupling assembly, as shown in the illustration.

Using SST, rotate the transmission coupling assembly forward and backward and measure the lateral runout.

SST

09564-32011

Maximum lateral runout:

0.07 mm (0.00276 in.)

Remove the 4 bolts and, using a plastic-faced hammer, lightly tap the rear differential carrier cover to remove it from the rear differential carrier.

NOTICE:

Set the brass bar on the ribbed part of the rear differential carrier cover.

Using a snap ring expander, remove the snap ring.

Remove the solenoid from the yoke.

Remove the O-ring from the solenoid.

Using a 5 mm socket hexagon wrench, remove the 3 bolts and yoke from the differential carrier.

Remove the spring washer from the differential carrier.

Remove the shim from the differential carrier.

Insert a dial gauge through the rear differential carrier cover plug hole, and set it perpendicular to the ring gear tooth surface's tip.

Using SST, fix the drive pinion in place.

SST

09556-16011

Using SST, rotate the rear differential case forward and backward, and measure the backlash.

SST

09564-32011

Standard backlash:

0.09 to 0.16 mm (0.00354 to 0.00630 in.)

NOTICE:

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

Using SST and a torque wrench, inspect the preload (starting torque) within the differential drive pinion and differential ring gear backlash area.

SST

09556-16011

Standard drive pinion preload:

0.24 to 0.37 N*m (2 to 4 kgf*cm, 2 to 3 in.*lbf)

NOTICE:

For a more accurate measurement, rotate the case bearing forward and backward before measuring.

Using SST and a torque wrench, inspect the preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.

SST

09556-16011

Standard total preload:

Standard drive pinion preload plus 0.99 to 1.63 N*m (10 to 17 kgf*cm, 9 to 14 in.*lbf)

NOTICE:

For a more accurate measurement, rotate the case bearing forward and backward before measuring.

Using SST, tap out the 2 rear differential side shaft gear oil seals from the rear differential carrier.

SST

09308-00010

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

SST

09308-10010

Using SST and a hammer, unstake the rear drive pinion nut.

SST

09930-00010

NOTICE:

1. Use SST with the tapered part against the shaft side.
   
2. Do not modify the SST tip with a grinder or equivalent.
   
3. Fully unstake the rear drive pinion nut.
   

Using SST, fix the differential drive pinion in place and remove the rear drive pinion nut from the differential drive pinion.

SST

09556-16011
09564-16020

Using SST, remove the rear driver pinion tapered roller bearing front (inner race) from the rear differential carrier.

SST

09556-30010

Remove the 8 bolts.

Using a brass bar and hammer, lightly tap out the differential side bearing retainer.

NOTICE:

Set the brass bar on the ribbed part of the differential side bearing retainer.

Remove the rear differential case from the rear differential carrier.

Remove the differential drive pinion from the rear differential carrier.

Remove the rear differential drive pinion bearing spacer from the differential drive pinion.

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

SST

09950-00020

NOTICE:

If the rear differential driver pinion or differential ring gear is damaged, replace them both.

Remove the rear differential drive pinion washer.

Using SST, remove the rear drive pinion tapered roller bearing front (outer race) from the rear differential carrier.

SST

09612-65014(09612-01020,09612-01050)

Using a brass bar and hammer, lightly and uniformly tap out the rear drive pinion tapered roller bearing rear (outer race).

NOTICE:

Set the brass bar on the notch.

Using SST and a press, press out the rear differential case bearing RH (outer race) and rear differential side gear shaft plate washer from the rear differential carrier.

SST

09950-60010
09950-70010(09951-07100)

Using SST and a press, press out the rear differential case bearing LH (outer race) and rear differential side gear shaft plate washer from the differential side bearing retainer.

SST

09950-60010(09951-00460)
09950-70010(09951-07100)
09649-17010

Using SST, remove the rear differential case bearing RH (inner race) from the rear differential case.

SST

09950-40011(09951-04010,09952-04010,09953-04020,09954-04010,09955-04061,09957-04010,09958-04011)
09950-60010(09951-00320,09955-04071)

NOTICE:

Before using SST center bolt (09953-04020), apply hypoid gear oil to its threads and tip.

Using SST, remove the rear differential case bearing LH (inner race) from the rear differential case.

SST

09950-40011(09951-04010,09952-04010,09953-04020,09954-04010,09955-04071,09957-04010,09958-04011)
09950-60010(09951-00320)

NOTICE:

Before using SST center bolt (09953-04020), apply hypoid gear oil to its threads and tip.

HINT:

If the race is remains on the rear differential case, repeat the step above to remove the race.

Place matchmarks on the rear differential case and differential ring gear.

Remove the 10 bolts.

Using a plastic-faced hammer, lightly tap the outer circumstance of the differential ring gear to remove it from the rear differential case.

Using a 5 mm socket hexagon wrench, remove the 2 bolts and rear differential breather plug oil deflector.

Using pliers, remove the 4 straight pins from the rear differential carrier.

Remove the bolt and bracket.