Part 1

DIFFERENTIAL CARRIER ASSY REAR (W/ DIFF.LOCK)








COMPONENTS

OVERHAUL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE REAR WHEEL
3. DRAIN BRAKE FLUID
4. REMOVE REAR BRAKE DRUM SUB-ASSY
5. REMOVE FRONT BRAKE SHOE
SST 09921-00010, 09718-00010
6. REMOVE REAR BRAKE SHOE
SST 09718-00010, 09718-00010
7. REMOVE PROPELLER SHAFT ASSY (2WD DRIVE TYPE, REGULAR CAB)
8. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (2WD DRIVE TYPE, EXCEPT REGULAR CAB)
9. REMOVE PROPELLER SHAFT ASSY (4WD DRIVE TYPE, REGULAR CAB)
10. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE, EXCEPT REGULAR CAB)
11. DRAIN DIFFERENTIAL OIL
12. SEPARATE SPEED SENSOR REAR LH
13. SEPARATE SPEED SENSOR REAR RH
14. SEPARATE PARKING BRAKE CABLE ASSY NO.3
15. SEPARATE PARKING BRAKE CABLE ASSY NO.2
16. REMOVE REAR AXLE SHAFT W/BACKING PLATE
17. REMOVE REAR AXLE SHAFT W/BACKING PLATE





18. REMOVE DIFFERENTIAL CARRIER ASSY REAR
a. Disconnect the differential lock actuator connector.
b. Disconnect the rear differential lock actuator breather hose from the differential actuator assembly.





c. Remove the 11 nuts and differential carrier assy.

NOTICE: Be careful not to damage the contact surfaces of the differential carrier and rear axle housing.

d. Remove the rear differential carrier gasket from the differential carrier assembly.





19. FIX DIFFERENTIAL CARRIER ASSY REAR
a. Fix the rear differential carrier assembly to the over attachment.





20. INSPECT REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
Maximum runout:
Vertical runout: 0.10 mm (0.0039 inch)
Lateral runout: 0.10 mm (0.0039 inch)
If the runouts are not with the specifications, replace the companion flange,





21. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
a. Using a dial indicator, check the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
If the runout is greater than the maximum, replace the ring gear with a new one.





22. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using a dial indicator, check the backlash of the ring gear.
Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)
If the backlash is not within the specification, adjust or repair the side bearing preload as necessary.





23. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the back lash between the drive pinion and ring gear.
Preload (at starting): 0.56 to 0.85 Nm (5.7 to 8.7 kgf-cm, 5.0 to 7.5 inch lbs.)
If necessary, disassemble and inspect the differential assy.





24. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
b. Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus 0.39 to 0.59 Nm (4.0 to 6.0 kgf-cm, 3.5 to 5.2 inch lbs.)
If necessary, disassemble and inspect the differential.





25. REMOVE DIFFERENTIAL LOCK SHIFT ACTUATOR
a. Remove the 4 bolts and actuator from the differential carrier.
b. Remove the O-ring.





26. REMOVE TRANSFER INDICATOR SWITCH NO.1
a. Remove the indicator switch and gasket.





27. REMOVE REAR DIFFERENTIAL LOCK SHIFT FORK SHAFT
a. Using a 6 mm hexagon wrench, remove the 2 screw plugs.
b. Remove the spring seat, spring and ball.





c. Using a 5 mm pin punch and hammer, remove the slotted pin.





d. Remove the 2 bolts from the shaft retainer.
e. Using a plastic hammer, remove the shaft retainer.
f. Remove the shift fork shaft.





28. REMOVE REAR DRIVE PINION NUT
a. Using SST and a hammer, loosen the staked part of the nut.
SST 09930-00010,





b. Using SST to hold the drive pinion companion flange, remove the nut.
SST 09330-00021





29. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using SST, remove the drive pinion companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)





30. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, remove the dust deflector.
SST 09950-60010 (09951-00380), 09950-70010 (09951-07150), 09950-00020





31. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
32. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER





33. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST, remove the drive pinion tapered roller bearing from the drive pinion.
SST 09556-22010





34. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK
a. Remove the 2 bolts and 2 rear differential bearing adjusting nut locks.





35. REMOVE DIFFERENTIAL CASE ASSY
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 4 bolts and 2 differential bearing caps.
c. Remove the 2 adjusting nuts.





d. Remove the rear differential case sub-assembly and 2 case bearings from the differential carrier.

HINT: Tag the 2 case bearings outer races to show the locations for reassembly.





36. REMOVE DIFFERENTIAL DRIVE PINION
a. Remove the differential drive pinion and bearing spacer from the differential carrier.





37. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, remove the drive pinion tapered roller bearing from the drive pinion.
SST 09950-00020

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

38. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER





39. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST, remove the front tapered roller bearing from the carrier.
SST 09308-00010
b. Using a brass bar and a hammer, remove the oil storage ring from the carrier.





40. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, remove the rear tapered roller bearing from the carrier.





41. REMOVE DIFFERENTIAL RING GEAR
a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver and a hammer, unstake the lock plates.
c. Remove the 10 ring gear set bolts and 5 lock plates.





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





42. INSPECT DIFFERENTIAL CASE ASSY RUNOUT
a. Install the rear differential case bearing onto the differential case.
b. Install the differential case onto the differential carrier.
c. Install the 2 bearing caps and 4 bolts onto the differential carrier.
Torque: 85 Nm (870 ft. lbs., 63 ft. lbs.)
d. Inspect the differential case runout.
Maximum runout: 0.07 mm (0.0028 inch)
e. Remove the differential case.
f. Remove the rear differential case bearing.





43. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the 2 rear differential case bearings from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)





44. DISASSEMBLE DIFFERENTIAL CASE
a. Place matchmarks on the LH and RH cases.
b. Remove the 8 bolts.





c. Using a plastic hammer, separate the LH and RH cases.





d. Remove these parts from the differential case.
(1) 2 side gears
(2) 2 side gear thrust washers
(3) Spider
(4) 4 pinion gears
(5) 4 pinion gear thrust washers





45. INSPECT REAR DIFFERENTIAL LOCK SLEEVE
a. Install the sleeve onto the differential case (LH) and check that it moves smoothly.
b. Install the side gear onto the sleeve and check that it moves smoothly.





c. Using a feeler gauge, measure the clearance between the shift fork and sleeve.
Maximum clearance: 0.15 to 0.35 mm (0.0059 to 0.0138 inch)
46. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
a. Check that there is no damage to the differential pinion and differential side gear.
If the differential pinion and/or differential side gear is damaged, replace the differential.
47. INSPECT DIFFERENTIAL CASE
a. Check that the differential case is not damaged.
If the differential case is damaged, replace the differential case.





48. INSTALL DIFFERENTIAL CASE ASSY
a. Install the rear differential side gear thrust washer onto the rear differential side gear.
b. Install the rear differential pinion thrust washer and rear differential pinion onto the rear differential spider.
c. Fix the differential case RH.





d. Install the rear differential side gear and rear differential spider onto the differential case RH.





e. Using a dial indicator, measure the differential case RH side backlash while holding the pinion toward the case.
Backlash: 0.05 to 0.20 mm (0.002 to 0.008 inch)
f. Remove the rear differential spider from the differential case RH.





g. Install the rear differential side gear and rear differential spider onto the differential case LH.
h. Using a dial indicator, measure the differential case LH side backlash while holding the pinion toward the case.
Backlash: 0.05 to 0.20 mm (0.002 to 0.008 inch)
If the backlash is not within the specification, install 2 side gear thrust washers of a different thickness.





Thrust washer thickness





i. Align the matchmarks and assemble the RH and LH cases.
j. Using a plastic hammer, install the differential case.
k. Install the 8 bolts.
Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)





49. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear to approximately 100°C (212°F) in boiling water.
c. Carefully take the ring gear out of the boiling water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case.





e. Align the matchmarks on the ring gear and differential case.
f. Temporarily install 5 new lock plates and 10 bolts.
g. After the ring gear cools down sufficiently, torque the 8 bolts uniformly.
Torque: 97 Nm (985 kgf-cm, 71 ft. lbs.)

HINT: Tighten the bolts in diagonal order little by little in several steps.





h. Using a chisel and a hammer, stake the 5 lock plates.

HINT: Stake one claw so that it is flush with the flat surface of the bolt. For the claw in contact with the protruding portion of the bolt, stake only the half on the tightening side.





50. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the bearing onto the differential case.
SST 09950-60010 (09951-00560, 09951-00570), 09950-70010 (09951-07150)





51. INSPECT DIFFERENTIAL RING GEAR RUNOUT
a. Install the differential case onto the carrier, and install the 2 adjusting nuts so that there is no play in the bearing.
b. Install the 2 bearing caps with the 4 bolts.
Torque: 85 Nm (870 kgf-cm, 63 ft. lbs.)
c. Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
d. Remove the 2 bearing caps, 2 adjusting nuts and differential case.





52. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
a. Using a press, install the dust deflector.

NOTICE: Be careful not to damage the dust deflector.

SST 09636-20010





53. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, install the oil storage ring.
b. Using SST and a press, install the tapered roller bearing onto the carrier.
SST 09316-60011 (09316-00011, 09316-00021)





54. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, install the tapered roller bearing onto the carrier.
SST 09316-60011 (09316-00041, 09316-00011)





55. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Install the plate washer onto the drive pinion.
b. Using SST and a press, install the tapered roller bearing onto the drive pinion.
SST 09506-30012