Rear Differential Carrier Assembly Disassembly

Secure the differential carrier.

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

Maximum Runout:

Runout	Maximum
Vertical runout	0.10 mm (0.00394 in.)
Lateral runout	0.10 mm (0.00394 in.)

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

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

Maximum runout:

0.07 mm (0.00276 in.)

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

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

Backlash:

0.13 to 0.18 mm (0.00512 to 0.00708 in.)

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

   HINT:

   Perform the measurement at 3 or more positions around the circumference of the ring gear.

Using a torque wrench, measure the preload.

Standard Preload (Starting Torque):

Item	Specified Condition
New bearing	1.1 to 1.6 N*m (12 to 16 kgf*cm, 10 to 14 in.*lbf)
Reused bearing	0.6 to 0.8 N*m (7 to 8 kgf*cm, 6 to 7 in.*lbf)

1. If the result is not as specified, adjust the preload.
   

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

Standard Total Preload:

Bearing	Specified Condition
New	0.4 to 0.5 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) + drive pinion preload
Reused	0.4 to 0.5 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) + drive pinion preload

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 with dust deflector.

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, remove the oil seal.

SST

09308-10010

Remove the oil slinger from the drive pinion.

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

SST

09556-22010

Remove the 2 bolts and 2 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 assembly from the differential carrier.

HINT:

Tag the 2 rear differential case bearings (outer) so that they can be reinstalled in the correct locations.

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

Using SST and a press, press out the roller bearing (inner) and drive pinion plate washer 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 bearings (outer) to the differential case.

Install the differential case to the differential carrier.

Install the 2 adjusting nuts.

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

Torque:

85 N*m{870 kgf*cm, 63 ft.*lbf}

Using a dial indicator, measure the differential case runout.

Maximum runout:

0.07 mm (0.00276 in.)

Remove the 4 bolts and 2 bearing caps.

Remove the 2 adjusting nuts.

Remove the differential case.

Remove the rear differential case bearings (outer).

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 bearings when not replacing the differential case.

Using a chisel and hammer, unstake the differential case.

Using a pin punch and hammer, tap out the straight pin.

Remove the following parts from the differential case.

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

Using a chisel and hammer, unstake the differential case.

Place matchmarks on the LH and RH cases.

Remove the 8 bolts.

NOTICE:

Diametrically loosen and remove the bolts in several passes.

Remove the following parts from the differential cases.

1. (1) Side gear (2 pieces)
   
2. (2) No. 1 Side gear thrust washer (6 pieces)
   
3. (3) Clutch plate (6 pieces)
   
4. (4) Side gear thrust washer (2 pieces)
   


5. (5) Spring retainer RH
   
6. (6) Spring retainer LH
   
7. (7) Compression spring
   
8. (8) Pinion gear (4 pieces)
   
9. (9) Pinion gear thrust washer (4 pieces)
   
10. (10) Spider
    

Using a micrometer, measure the thickness of the thrust washer. Also, check that there is no bare metal.

Standard thickness:

1.77 to 1.86 mm (0.0697 to 0.0732 in.)

1. If necessary, replace the thrust washers.
   

   HINT:

   If replacing the thrust washer, also replace the clutch plate that it contacts.

Using a micrometer, measure the thickness of the clutch plate. Also, check that there is no abnormal wear.

Standard thickness:

1.57 to 1.63 mm (0.0619 to 0.0641 in.)

1. If necessary, replace the clutch plate.
   

Using a vernier caliper, measure the free length of the spring.

Minimum free length:

27.02 mm (1.063 in.)

1. If the length is less than the minimum, replace the spring.
   

Check that the differential pinion and differential gear are not damaged.

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

Check that the differential case is not damaged.

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