Rear Differential Assembly Disassembly

Rear Differential Assembly Disassembly and Reassembly

Disassembly
1) Drive out rear drive right and left shaft using special tools.
Special Tool
(A):09942-15511
(B):09943-17912





2) Remove rear drive right and left retainers.
3) Tapping rear cover flanges with plastic hammer, remove rear cover (1) and dynamic damper (if equipped).





4) Disassembly rear drive right retainer as follows, if necessary.
a) Remove oil seal (1) using special tool.
Special Tool
(A):09913-50121





b) Remove snap ring.





c) Drive out rear drive shaft bearing using special tools.
Special Tool
(A):09930-30104
(B):09941-64511





5) Disassembly rear drive left retainer in the same manner at Step 4), if necessary.
6) Take out differential assembly (1), outer race and shim all at once.





7) Pull out differential side bearing (1) using special tools.
Special Tool
(A):09913-65135
(B):09925-86010





8) Remove drive bevel gear (hypoid gear), differential gears, differential pinions and pinion shaft as follows.
a) With aluminum plates (2) placed on vise first, grip differential case with it and remove drive bevel gear (hypoid gear) (3) by removing its bolts (1).





b) Remove pinion shafts (1), differential gears, washers, differential pinions, spring washers, thrust washers and pinion joint.





9) Remove drive bevel pinion (hypoid gear) assembly as follows.
a) Hold joint flange with special tool and then remove flange nut by using power wrench (4 - 10 magnification) (2).
Special Tool
(A):09922-66021








b) Make mating marks (1) on drive bevel pinion and companion flange.

CAUTION:
Do not make mating mark on the coupling surface of the flange.

c) Remove flange (2) from drive bevel pinion. Use special tool if it is hard to remove.
Special Tool
(A):09913-65135
(B):09925-88210





d) Remove drive bevel pinion (1) with rear bearing, shim and spacer from carrier. If it is hard to remove, screw an used nut (2) into drive bevel pinion and hammer (3) on that nut with a plastic hammer but never directly on drive bevel pinion.





e) Remove drive bevel pinion rear bearing (2) by using bearing puller (3) and hydraulic press.

CAUTION:
To avoid rear bearing from being damaged, support it at flat side of bearing puller.








10) Remove oil seal (1) using special tool.
Special Tool
(A):09913-50121





11) Using a hammer and brass bar (1), drive out front bearing outer race (2).





12) Drive out rear bearing outer race (1) in the same manner as Step 11).