Disassembly
REAR DIFFERENTIAL CARRIER
COMPONENTS
DISASSEMBLY
1. CHECK COMPANION FLANGE RUNOUT
Using a dial indicator, measure the vertical and lateral runout of the companion flange.
Maximum runout: 0.09 mm (0.0035 inch)
If the runout exceeds the maximum, replace the companion flange.
2. CHECK RING GEAR RUNOUT
Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 inch)
If the runout exceeds the maximum, replace the ring gear.
3. CHECK RING GEAR BACKLASH
Using a dial indicator, while holding the companion flange, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
HINT: Measure at 3 or more positions around the circumference of the ring gear.
If the backlash is not within the specified value, adjust the side bearing preload or repair as necessary.
4. CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
5. CHECK SIDE GEAR BACKLASH
Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specified value, replace the side gear thrust washer of the different thickness.
6. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the drive pinion using the backlash between the drive pinion and ring gear.
Preload (at starting): 0.8 - 1.1 Nm (8 - 11 kgf-cm, 7.0 - 9.7 inch lbs.)
7. CHECK TOTAL PRELOAD
Using a torque wrench, measure the total 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 (4 - 6 kgf-cm, 3.5 - 5.2 inch lbs.)
If necessary, disassemble and inspect the differential.
8. REMOVE COMPANION FLANGE
a. Using a chisel and hammer, unstake the staked part of the nut.
b. 2WD: Remove the companion flange nut.
1. Using a Torx socket (E8), remove the stud bolt and loosen the 3 bolts so that the heads come out 40 mm (1.57 inch).
2. Set the SST and install the 3 nuts to the companion flange.
SST 09213-58013
3. Install the other SST to the set SST to hold the companion flange, and remove the nut.
SST 09330-00021
4. Remove the 3 nuts, stud bolts and SST from the companion flange.
c. 4WD: Using SST to hold the flange, remove the nut.
SST 09330-00021
d. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03050)
9. REMOVE FRONT OIL SEAL
Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
10. REMOVE FRONT BEARING AND BEARING SPACER
a. Using SST, remove the bearing from the drive pinion.
SST 09556-22010
If the front bearing is damaged or worn, replace the front bearing.
b. Remove the 2 washers and bearing spacer.
11. REMOVE DIFFERENTIAL CASE
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 4 bolts and bearing cap.
c. Using SST and a plastic hammer, remove the 2 side bearing plate washers.
SST 09504-22012
HINT: Measure the plate washer thickness and note it down.
d. Remove the differential case with the bearing outer races from the carrier.
HINT: Tag the bearing outer races to show the location for reassembling.
12. REMOVE DRIVE PINION FROM DIFFERENTIAL CARRIER
Remove the drive pinion with the rear bearing.
13. REMOVE DRIVE PINION REAR BEARING
Using SST and a press, remove the bearing from the drive pinion.
SST 09950-00020
HINT: If the drive pinion or ring gear is damaged, replace them as a set.
14. REMOVE FRONT AND REAR BEARING OUTER RACES AND ADJUSTING WASHER
NOTICE: Do not remove the outer races except when replacing the bearings.
Using a brass bar and hammer, remove the outer races and adjusting washer from the carrier.
HINT: Measure the adjusting washer thickness and note it down.
15. REMOVE RING GEAR
a. Place matchmarks on the ring gear and differential case.
b. Remove the 12 ring gear set bolts.
c. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
16. CHECK DIFFERENTIAL CASE RUNOUT
a. Install the differential case in the differential carrier.
b. Using a dial indicator, measure the differential case run out.
Maximum case runout: 0.04 mm (0.0016 inch)
c. Remove the differential case.
17. REMOVE SIDE BEARINGS
Using SST, remove the 2 side bearings from the differential case.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00480)
HINT: Fix the claws of SST to the notch in the differential case.
18. DISASSEMBLE DIFFERENTIAL CASE ASSEMBLY
a. Using a pin punch and hammer, remove the straight pin.
b. Remove the pinion shaft, 2 pinion gears, pinion gear thrust washers, side gears and side gear thrust washers from the differential case.