Rear Differential Carrier (For 2Ad-Fhv) Disassembly

Remove the breather plug from the differential carrier cover.

Remove the 8 bolts from the differential carrier cover.

Using a brass bar and a hammer, remove the differential carrier cover from the differential carrier.

NOTICE:

1. Place the brass bar onto the corners of the carrier cover.
   
2. 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 the overhaul stand, etc., as shown in the illustration.

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

Rotate the ring gear and measure the backlash.

Maximum runout:

0.05 mm (0.0020 in.)

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

Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

Coat 3 or 4 teeth at the 3 different positions on the ring gear with Prussian blue.

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 plate washer for correction.

HINT:

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.
   

Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0 mm (0 in.).
If not, replace the rear differential case sub-assembly with a new one.

Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 in.) away from the end of the shaft.

Maximum runout:

0.08 mm (0.0031 in.)

Using SST and a torque wrench, measure the starting torque of the drive pinion. The backlash between the drive pinion and ring gear should allow enough movement of the drive pinion to allow this measurement to be performed. Make sure not to include the preload of the ring gear (differential case) in the measurement of the drive pinion preload.

SST

09229-55010

Drive pinion preload (at starting):

Specifications	Preload
New bearing	1.22 to 1.80 N*m (12.4 to 18.4 kgf*cm, 10.8 to 15.9 in.*lbf)
Reused bearing	0.50 to 0.80 N*m (5.1 to 8.2 kgf*cm, 4.3 to 6.9 in.*lbf)

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

SST

09229-55010

Total preload (at starting):

Grade: luxury

Specifications	Preload
New bearing	1.92 to 3.89 N*m (19.6 to 39.7 kgf*cm, 17.0 to 34.4 in.*lbf)
Reused bearing	1.20 to 2.89 N*m (12.2 to 29.5 kgf*cm, 10.6 to 25.6 in.*lbf)

Grade: sport

Specifications	Preload
New bearing	1.75 to 3.38 N*m (17.8 to 34.5 kgf*cm, 15.5 to 29.9 in.*lbf)
Reused bearing	1.03 to 2.38 N*m (10.5 to 24.3 kgf*cm, 9.1 to 21.1 in.*lbf)

Using SST, remove the 2 oil seals.

SST

09308-00010

Install SST to the differential carrier.

SST

09571-50010

Tighten the SST bolt (A) until the SST disc slightly touches the case bearing outer race.

Install a dial indicator to the rear differential carrier.

Tighten the SST bolt. Push in the differential case bearing (outer race) until an approximately 0.1 mm (0.004 in.) clearance is created between the bearing (outer race) and the differential side gear shaft snap ring.

NOTICE:

Observe the dial indicator and ensure that the bearing (outer race) is not pushed in more than 0.2 mm (0.008 in.).

HINT:

1. Install the dial indicator to the position as close to the differential carrier cover side (upper side in the illustration) of the bearing (outer race) as possible.
   
2. Approximately 0.1 mm (0.004 in.) clearance between the case bearing outer race and the side gear shaft snap ring is sufficient for the washer to move slightly.
   

Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.

HINT:

For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result.

Remove the dial indicator and loosen the SST bolt.

NOTICE:

Do not remove the SST.

Using SST and a hammer, create a clearance between the case bearing outer race on the back surface of the ring gear and side gear shaft snap ring.

SST

09608-32010
09950-70010(09951-07200)

HINT:

The clearance is not visible, but tapping the SST with a hammer three or four times should create sufficient clearance.

Using snap ring pliers, remove the side gear shaft snap ring on the back surface of the ring gear.

HINT:

For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result.

Tighten the SST bolt and push out the case bearing outer race on the back surface of the ring gear.

SST

09571-50010

NOTICE:

Do not drop the case bearing outer race.

Remove the SST.

Raise the ring gear of the differential case slightly to remove the ring gear tooth side case bearing outer race.

HINT:

For reassembly, check the installation position of the case bearing outer race and the side gear shaft snap ring before removing the case bearing outer race. Write down the result.

Remove the rear differential case assembly.

NOTICE:

Do not damage the case bearing.

Using SST and a hammer, unstake the staked part of the drive pinion nut.

SST

09930-00010

NOTICE:

1. Be sure to use the 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

09229-55010
09330-00021
09950-30012(09955-03040)

Using SST, remove the companion flange.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03040,09956-03060)

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

09950-60010(09951-00440)
09950-00020
09950-70010(09951-07100)

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

SST

09308-00010

Remove the drive pinion oil slinger.

Using a press, remove the drive pinion from the differential carrier.

NOTICE:

Do not drop the drive pinion.

Remove the drive pinion spacer.

Remove the rear drive pinion front tapered roller bearing inner race from the differential carrier.

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

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

SST

09950-00020

HINT:

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

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

Remove the plate washer.

Put machmarks on the ring gear and differential case.

Remove the 10 ring gear set bolts.

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

NOTICE:

Do not damage the ring gear.

Install the differential case to the differential carrier.

NOTICE:

Do not damage the case bearing.

Using SST and a hammer, install the case bearing outer race on the ring gear tooth side.

SST

09608-32010
09950-70010(09951-07200)

HINT:

Tap in the case bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.

Install SST to the differential carrier.

SST

09571-50010

Tighten the SST bolt (A) until the SST disc slightly touches the case bearing outer race.

Using SST and a hammer, install the case bearing outer race on the ring gear back surface side.

SST

09608-32010
09950-70010(09951-07200)

HINT:

Tap in the case bearing outer race until it touches the case bearing inner race roller.

Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.

Place a dial indicator on the differential case flange surface at a right angle.

Using a dial indicator, measure the differential case runout.

Maximum runout:

0.05 mm (0.0020 in.)

Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.

Tighten the SST bolt to push out the ring gear back surface side case bearing outer race.

SST

09571-50010

NOTICE:

Do not drop the case bearing outer race.

Remove the SST.

Raise the ring gear side of the differential case slightly to remove the ring gear tooth side case bearing outer race.

Remove the differential case from the differential carrier.

NOTICE:

Do not damage the case bearing.

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(09951-00350,09951-00480,09952-06010)

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.
   

Hold the differential case in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

Place a dial indicator on the tip of the side gear tooth at a right angle. Hold the pinion gear in the differential case and check that the backlash is 0 mm (0 in.).
If not, replace the rear differential case sub-assembly with a new one.