Disassembly

Rear Differential Carrier (2 Of 3) W/O Differential Lock:

Rear Differential Carrier (3 Of 3) With Differential Lock:

DISASSEMBLY





1. Check the runout of the companion flange.
Using a dial indicator, measure the vertical and lateral runout of the companion flange.
Maximum runout:
Vertical runout: 0.10 mm (0.0039 inch)
Lateral runout: 0.10 mm (0.0039 inch)
If the runout are not within the specification, replace the companion flange.





2. Check ring gear runout.
Using a dial indicator, check and measure the ring gear runout.
Maximum runout: 0.07 mm (0.0028 inch).
If the runout is not within the specification, replace the ring gear.





3. Check ring gear backlash.
Using a dial indicator, check, then measure the ring gear backlash.
Backlash: 0.13-0.18 mm (0.0051-0.0071 inch).
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.





4. Measure drive pinion preload.
Using a torque wrench, measure the drive preload of backlash between the drive pinion and ring gear.
Preload (at starting): 0.5-0.8 Nm (4.3-6.9 inch lbs.).





5. Check total preload.
Using a torque wrench, check, then measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus: 0.4-0.6 Nm (3.5-5.2 inch lbs.).
If necessary, disassemble and inspect the differential.
6. Check the tooth contact between the ring gear and the drive pinion.
7. w/ Diff. lock:
Remove the actuator.





a. Remove the bolt and actuator from the differential carrier.
b. Remove the O-ring.





8. w/ Diff. lock:
Remove indicator switch and gasket.
Remove the indicator switch and gasket.
9. w/ Diff. lock:
Remove the shift fork shaft.
a. Using a hexagon wrench, remove the two straight screw plugs.





b. Remove the spring seat, compression spring and ball.





c. Using a pin punch and hammer, remove the slotted spring pin.
d. Remove the two bolts from the shaft retainer.





e. Using a plastic hammer, remove the shaft retainer.
f. Remove the shift fork shaft.

HINT: Pull out the shift fork shaft with a screwdriver turned round.

10. Remove the companion flange.
a. Using a chisel and hammer, unstake the nut.





b. Using the Special Service Tool (SST) 09330-00021 to hold the flange, remove the nut.





c. Using the SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956 03030), remove the companion flange.

11. Remove the oil seal and the oil slinger.





a. Using the SST 09308-10010, remove the oil seal from the differential carrier.
b. Remove the oil slinger.





12. Remove front bearing.
Using the SST 09556-22010, remove the front bearing from the drive pinion.
13. w/ Diff. lock:
Remove the differential case.





a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the two adjusting nut locks.
c. Remove the four bolts and two bearing caps.
d. Remove the two adjusting nuts.
e. Remove the differential case with the side bearing outer races from the differential carrier.

HINT: Tag the disassembled parts to show the location for reassembly.

14. w/ Diff. lock:
Remove differential case.





a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the two adjusting nut locks.
c. Remove the four bolts and two bearing caps.
d. Remove the differential case with side bearing outer races, adjusting nut and sleeve from the differential carrier.
e. Remove the shift fork.





15. Remove the drive pinion and the bearing spacer.
a. Remove the drive pinion with the rear bearing.
b. Remove the bearing spacer.
16. Remove the drive pinion rear bearing.





a. Using the SST 09950-00020 and a press, remove the bearing from the drive pinion.

HINT: If the drive pinion or the ring gear are damaged, replace them as a set.

b. Remove the plate washer from the drive pinion.
17. Remove the front and rear bearing outer races and the oil storage ring.





a. Using the SST 09308-00010, remove the front bearing outer race.
b. Using a brass bar and hammer, remove the oil storage ring.
c. Using a brass bar and hammer, remove the rear bearing outer race.





18. Remove the ring gear.
a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver and hammer, unstake the five lock plates.
c. Remove the ten ring gear set bolts and five lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
19. w/o Diff. lock:
Check the differential case runout.
a. Place the bearing outer races on their respective bearings. Check that the left and right outer races are not interchanged.
b. Install the differential case in the differential carrier.
c. When there is no play left in the side bearings, install the plate washers.
d. Align the matchmarks on the bearing cap and differential carrier.
e. Install and uniformly tighten the 4 bearing cap bolts in several passes.





f. Using a dial indicator, measure the differential case run out.
Maximum runout: 0.07 mm (0.0028 inch).
g. Remove the differential case.
20. w/ Diff. lock:
Check differential case runout.
a. Install the differential case in the differential carrier and tighten the adjusting nut just to where there is no play in the bearing.





b. Using a dial indicator, measure the differential case run out.
Maximum runout: 0.07 mm (0.0028 inch).
c. Remove the differential case.





21. Remove side bearing from differential case.
Using the SST 09950-40010 (09951-04010, 09952-04010, 09953-04020, O9954-04010, 09955-04060, 09957-04010, 09958-04010), 09950-60010 (09951-00480), 09950-60020 (09951-00730), remove the side bearing(s) from the differential case.

HINT: Fix the claws of SST to the notches in the differential case.

22. Disassemble the differential case.





a. Place matchmarks on the left and right hand cases.
b. Remove the eight bolts uniformly, a little at a time.
c. Using a plastic hammer, separate the left and right hand cases.
d. Remove these parts:
- 2 side gears.
- 2 side gear thrust washers.
- Spider.
- 4 pinion gears spider.
- 4 pinion gear thrust washers.
23. w/ Diff. lock:
Inspect the sleeve.





a. Install the sleeve to the left hand differential case and check that it moves smoothly.
b. Install the sleeve to the side gear and check it moves smoothly.





24. w/ Diff. lock:
Measure the clearance between the shift fork and sleeve.
Using a feeler gauge, measure the clearance between the shift fork and sleeve.
Clearance (Reference): 0.15-0.35 mm (0.006-0.014 inch).

REPLACEMENT
Replace the companion flange dust deflector.





a. Using the SST 09950-00020 and a press, remove the dust deflector.





b. Using the SST 09726-40010 and a press, install a new dust deflector.