Rear Differential Carrier Disassembly

Remove the breather plug from the differential carrier cover.

Remove the 8 bolts from the differential carrier cover.

Using a brass bar and hammer, lightly tap the rib of the side bearing retainer to remove it.

NOTICE:

Do not damage the sealing surface of the differential carrier.

Remove the bolt and oil deflector from the differential carrier cover.

Set the differential carrier to an overhaul stand, etc., as shown in the illustration.

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

Maximum runout:

0.07 mm (0.0028 in.)

Set the dial indicator perpendicular to the end of the ring gear face.

While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

Backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

HINT:

1. Record the measured backlash to use as a reference for selecting a side gear shaft plate washer.
   
2. Inspect tooth contact to use the result as a reference for selecting a side gear shaft plate washer.
   

Select a side gear shaft plate washer that will set ring gear backlash within the specified range, and install it to the ring gear back side.

Make the differential case bearing and side gear shaft plate washer snug by tapping on the ring gear with a plastic hammer.

Set the dial indicator perpendicular to the end of the ring gear face.

While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.

Backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

If the backlash is not within the specified range, select a side gear shaft plate washer that will set the ring gear backlash within the specified range and install it into the ring gear back side.

Select a thicker side gear shaft plate washer so that the clearance between the case bearing outer race end on the ring gear teeth side and the carrier becomes zero or close to zero.

Make the differential case bearing and side gear shaft plate washer snug by tapping on the ring gear with a plastic hammer.

Set the dial indicator perpendicular to the end of the ring gear face.

While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

Backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.

Rotate the ring gear in both directions.

Inspect the tooth contact pattern.

If the teeth are not contacting properly, use the following table to select a proper washer for correction.

NOTICE:

1. If the contact pattern is face contact or flank contact, tooth contact may be adjustable while keeping the backlash within the specified range.
   
2. If the thickness of the drive pinion washer has been changed, adjust the backlash and measure the total preload.
   

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

Maximum runout:

0.09 mm (0.0035 in.)

Using a torque wrench, measure the preload of the drive pinion.

Preload (at starting):

Specifications	Drive pinion preload
New bearing	1.49 to 2.59 N*m (15.2 to 26.4 kgf*cm, 13.2 to 22.9 in.*lbf)
Reused bearing	1.11 to 1.91 N*m (11.3 to 19.5 kgf*cm, 9.8 to 16.9 in.*lbf)

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

Preload (at starting):

Specifications	New drive pinion tapered roller bearing	Reused drive pinion tapered roller bearing
New differential case bearing	2.57 to 4.26 N*m (26.2 to 43.4 kgf*cm, 22.7 to 37.7 in.*lbf)	2.19 to 3.58 N*m (22.3 to 36.5 kgf*cm, 19.4 to 31.7 in.*lbf)
Reused differential case bearing	1.98 to 3.37 N*m (20.2 to 34.4 kgf*cm, 17.5 to 29.8 in.*lbf)	1.60 to 2.69 N*m (16.3 to 27.4 kgf*cm, 14.2 to 23.8 in.*lbf)

Using SST, remove the 2 oil seals.

SST

09308-00010

Using SST and a hammer, unstake the staked part of the drive pinion 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 the SST with a grinder, etc.
   
3. Completely loosen the staked part of the nut when removing it.
   
4. Do not damage the threads of the drive pinion.
   

Using SST to hold the flange, remove the drive pinion nut.

SST

09330-00021

Using SST, remove the companion flange.

SST

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

NOTICE:

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

Using SST and a press, remove the dust deflector.

SST

09950-00020
09950-60010(09951-00380)
09950-70010(09951-07100)

NOTICE:

Do not drop the companion flange.

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

SST

09308-00010

Remove the drive pinion oil slinger.

Using SST, remove the inner race of the rear drive pinion front tapered roller bearing from the drive pinion.

SST

09556-22010

NOTICE:

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

Remove the drive pinion bearing spacer.

Put matchmarks on either set of the bearing cap and differential carrier.

Remove the 4 bolts and 2 bearing caps.

NOTICE:

Do not swap bearing caps, as each cap is only suitable for its original location and installation direction on the carrier it was manufactured on.

Using SST and a hammer, remove the 2 side gear shaft plate washers.

SST

09504-22011

NOTICE:

Put identification marks on the side gear shaft plate washer to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.

HINT:

Measure the thickness of the plate washers and note it.

Remove the differential case assembly and the case bearing outer races LH and RH from the differential carrier.

NOTICE:

1. Do not damage the differential case bearing or ring gear.
   
2. Put identification marks on the case bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.
   

Remove the drive pinion from the differential carrier.

Using SST and a press, remove the inner race of the rear drive pinion rear tapered roller bearing from the drive pinion.

SST

09950-00020

NOTICE:

Do not drop the drive pinion.

HINT:

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

Remove the drive pinion plate washer from the drive pinion.

HINT:

Measure the thickness of the plate washer and note it.

Using a brass bar and a hammer, remove the outer race of the rear drive pinion front tapered roller bearing from the differential carrier.

NOTICE:

Place the brass bar onto the outer race of the rear drive pinion front tapered roller bearing. Do not damage the differential carrier.

Using a brass bar and a hammer, remove the outer race of the rear drive pinion rear tapered roller bearing from the differential carrier.

NOTICE:

Place the brass bar onto the outer race of the rear drive pinion front tapered roller bearing. Do not damage the differential carrier.

Hold the differential case in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

Put matchmarks on the ring gear and differential case.

Using a chisel and a hammer, unstake the 5 lock plates.

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

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

HINT:

Use cloth to prevent damage to the ring gear teeth.

Install the case bearing outer races LH and RH to the case bearing inner races LH and RH respectively.

NOTICE:

1. Be sure to install the bearing outer races in each correct position.
   
2. Do not damage the differential case bearing or ring gear.
   

Install the differential case to the differential carrier.

Install the right and left (back side and teeth side) side gear shaft plate washers so that there is no looseness on the case bearings.

Align the matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps.

NOTICE:

Make sure that the right and left bearing caps are not interchanged.

Tighten both bearing caps with the 4 bolts.

Torque:

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

Using a dial indicator, measure the differential case runout.

Maximum case runout:

0.07 mm (0.0028 in.)

Remove the 4 bolts and 2 bearing caps.

NOTICE:

Do not swap bearing caps, as each cap is only suitable for its original location and installation direction on the carrier it was manufactured on.

Remove the right and left bearing caps, 2 side gear shaft plate washers and differential case.

NOTICE:

Do not damage the differential case bearing or ring gear.

Hold the differential case in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

Using SST, remove the case bearing inner races LH and RH from the differential case.

SST

09950-40011(09951-04020,09952-04010,09953-04030,09954-04010,09955-04061,09957-04010,09958-04011)
09950-60010(09951-00480,09951-00350,09952-06010)

NOTICE:

1. Do not deform the bearing cage if the bearing is to be reused.
   
2. Hook the SST claw from the dent of the differential case to the bearing inner race.
   
3. Apply grease to the threads and tip of the SST center bolt before use.