Part 1

DIFFERENTIAL CARRIER ASSY REAR (W/O 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. Remove the 10 nuts and differential carrier assy.

NOTICE: Be careful not to damage the removal surface.

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

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

20. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using a dial indicator, measure the vertical and horizontal 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 runouts are not within 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: 0.05 mm (0.0020 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): 0.78 to 1.05 Nm (8.0 to 11 kgf-cm, 6.9 to 9.3 inch lbs.)

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 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

26. 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)

27. 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

28. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010

29. 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

30. REMOVE DIFFERENTIAL CASE ASSY
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.

HINT: Measure the plate washer thickness and note it down.

SST 09504-22011
d. Remove the differential case with the bearing outer races from the carrier.

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

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

32. 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 are damaged, replace them as a set.

33. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

34. 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.

35. 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.

36. REMOVE DIFFERENTIAL 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.

37. 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. Using a dial indicator, measure the differential case run out.
Maximum case runout: 0.05 mm (0.0020 inch)
d. Remove the differential case.

38. 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, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00480)

HINT: Fix the claws of SST into the notch in the differential case.

39. DISASSEMBLE DIFFERENTIAL CASE (2 PINION DIFFERENTIAL)
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.

40. DISASSEMBLE DIFFERENTIAL CASE (W/LSD DIFFERENTIAL)
a. Place matchmarks on the LH and RH cases.
b. Remove the 8 bolts uniformly, a little at a time.
c. Using a plastic hammer, separate the LH and RH cases.

d. Remove these parts from the LH case.
(1) Remove the side gear.
(2) Remove the 4 side gear thrust washers.
(3) Remove the 3 clutch plates.

HINT:
^ Keep the disassembled parts in order.
^ Face the rough side of the thrust washer marked by "#" to the differential case.

e. Remove these parts from the RH case.
(1) Spring LH retainer.
(2) Compression spring.
(3) Differential pinion gear.
(4) Spring RH retainer.
(5) Pinion gear thrust washer.
(6) Spider

(7) Side gear.
(8) 5 side gear thrust washers.
(9) 4 clutch plates.

HINT: Face the rough side of the thrust washer marked by "#" to the differential case.

41. DIFFERENTIAL SIDE GEAR (W/LSD DIFFERENTIAL)
a. Check that there is no damage or wear to the side gear. If the side gear is damaged or worn, replace the side gear. If replacing the side gear, also replace the thrust washer that contacts with it.

42. INSPECT REAR DIFFERENTIAL SIDE GEAR THRUST NO.1 WASHER (W/LSD DIFFERENTIAL)
a. Using a micrometer, confirm that the contact surface of the thrust washer is even and check that no bare metal is showing.
Standard thickness: 1.77 to 1.86 mm (0.0697 to 0.0732 inch)
If necessary, replace the thrust washers.

HINT: When replacing the thrust washer, also replace the clutch plate that comes into contact with it.

43. INSPECT CLUTCH PLATE (W/LSD DIFFERENTIAL)
a. Using a micrometer, measure the contact surface of the clutch plate and check that there is no abnormal wear.
Standard thickness: 1.57 to 1.63 mm (0.0618 to 0.0642 inch)
If necessary, replace the clutch plate.

44. INSPECT REAR DIFFERENTIAL LOCK RETAINER COMPRESSION SPRING (W/LSD DIFFERENTIAL)
a. Using a vernier calipers, measure the free length of the spring.
Free length: 26.35 mm (1.037 inch)
45. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
a. Check that there is no damage to the differential pinion or differential side gear. If the differential pinion and/or differential side gear is damaged, replace the differential.
46. INSPECT DIFFERENTIAL CASE
a. Check that the differential case is not damaged. If the differential case is damaged, replace it.

47. INSTALL DIFFERENTIAL CASE ASSY (W/LSD DIFFERENTIAL)
a. LH side:
(1) Measure dimension A1 of the differential case, as shown in the illustration.
(2) Install the thrust washers with their fine side facing to the side gear, and clutch plates onto the side gear.

HINT: Install the new thrust washer (Mark N) instead of the thrust washers (Mark A - M) onto the differential case side.

(3) Using SST to press down the thrust washers and clutch plates with pressure of about 10 kgf (22 lbs), measure dimension B1 as shown in the illustration.
SST 09649-17010
(4) Refer to the table and select the proper adjusting shim(s).
Adjusting shim thickness = A1 - B1 -16.175 mm (0.63681 inch)

b. RH side:
(1) Measure the differential case dimension A2, as shown in the illustration.
(2) Install the thrust washers with their fine side facing to the side gear, and clutch plates on the side gear.

HINT: Install the new thrust washer (Mark N) instead of the thrust washers (Mark A - M) onto the differential case side.

Adjust washer thickness

HINT: Three or two adjusting shims can be used together if the total of their thickness meets the one of the above combinations, even if the combination does not exist in the above table.

(5) Side gear thrust shim.
(6) Side gear thrust washer No.1.
(7) Clutch plate.
(8) Side gear.

c. Install the 4 pinion gears and thrust washers onto the spider.
d. Align the spring RH retainer holes with the spider knock pins and install the RH retainer.
e. Install the pinion gear and spider onto the differential RH case.

HINT: Install the spider tightly onto the RH case while holding the spring retainer.

f. Using a dial indicator, measure the side gear backlash while holding the side gear and spider.
Backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 inch)

HINT:
^ Measure the backlash at all 4 locations.
^ Measure the backlash at the LH and RH cases.

If the backlash is not within the specification, install a adjusting shim of a different thickness.
g. Reinstall the spider and spring RH retainer onto the differential RH case.

HINT: Install the spider tightly onto the RH case while holding the spring retainer.

h. Install the compression spring and spring LH retainer.

i. Install the side gear, thrust washers and clutch plates.
j. Align the matchmarks and assemble the RH and LH cases.

HINT: Be careful not to drop the side gear and check the pinion and side gear alignment.

k. Tighten the 8 bolts uniformly, a little at a time.
Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)