Disassembly

DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY: DISASSEMBLY

DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY: DISASSEMBLY

1. REMOVE REAR DIFFERENTIAL CARRIER GASKET
2. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY
3. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY 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 in.)
Lateral runout: 0.10 mm (0.0039 in.)
If the runouts are not with the specifications, replace the companion flange.
4. 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 in.)
If the runout is greater than the maximum, replace the ring gear with a new one.
5. 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 in.)
If the backlash is not within the specification, adjust or repair the side bearing preload as necessary.
6. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD






(a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting):
0.56 to 0.85 N*m (5.7 to 8.7 kgf*cm, 5.0 to 7.5 in.*lbf)
If necessary, disassemble and inspect the differential assembly.
HINT: Before measurement, rotate the ring gear 5 times or more.

7. INSPECT TOTAL PRELOAD






(a) 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 0.39 to 0.59 N*m (4.0 to 6.0 kgf*cm, 3.5 to 5.2 in.*lbf)
If necessary, disassemble and inspect the differential.
8. REMOVE REAR DRIVE PINION NUT






(a) 2WD drive type:
Using a "Torx" socket (E10), remove the 4 stud bolts.
(b) Using SST and a hammer, unstake nut.
SST: 09930-00010






(c) Using SST to hold the drive pinion companion flange, remove the nut.
SST: 09330-00021
09330-00030
9. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR






(a) Using SST, remove the drive pinion companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03030
10. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL






(a) Using SST, remove the oil seal from the differential carrier.
SST: 09308-10010
11. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
12. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING






(a) Using SST, remove the front bearing from the drive pinion.
SST: 09556-22010
13. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK






(a) Remove the 2 bolts and 2 rear differential bearing adjusting nut locks.
14. REMOVE DIFFERENTIAL CASE ASSEMBLY






(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 assembly and 2 bearing outer races from the differential carrier assembly.
HINT: Tag the 2 bearings outer races to show the locations for reassembly.

15. REMOVE DIFFERENTIAL DRIVE PINION






(a) Remove the differential drive pinion and bearing spacer from the differential carrier assembly.
16. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING






(a) Using SST and a press, remove the rear bearing from the drive pinion.
SST: 09950-00020
HINT: If either the drive pinion or ring gear is damaged, replace them as a set.

17. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER
(a) Remove the plate washer from the drive pinion.
18. REMOVE FRONT BEARING OUTER RACE






(a) Using a brass bar an a hammer, remove the front bearing outer race from the differential carrier assembly.
19. REMOVE DIFFERENTIAL OIL STORAGE RING
(a) Using a brass bar and a hammer, remove the oil storage ring.
20. REMOVE REAR BEARING OUTER RACE






(a) Using a brass bar and a hammer, remove the rear tapered roller bearing from the carrier.
21. REMOVE DIFFERENTIAL RING GEAR






(a) Place matchmarks on the ring gear and differential case assembly.
(b) Using a screwdriver and a hammer, unstake the 5 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 assembly.
22. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT
HINT: It will be done only when it exceeds the limit at the ring gear runout check.





(a) Install the differential case assembly to the differential carrier assembly.
(b) Align the matchmarks, install the 2 bearing caps with the 4 bolts to the differential carrier assembly.
Torque: 85 Nm (867 kgf-cm, 63 ft-lbf)
(c) Inspect the differential case runout.
Maximum runout:
0.07 mm (0.0028 in.)
(d) Remove the 4 bolts and bearing caps from the differential carrier assembly.
(e) Remove the differential case assembly from the differential carrier assembly.
23. REMOVE REAR DIFFERENTIAL CASE BEARING






(a) Using SST, remove the 2 rear differential case bearings from the differential case assembly.
SST: 09950-40011
09951-04010
09952-04010
09953-04020
09954-04010
09955-04061
09957-04010
09958-04011
SST: 09950-60010
09951-00480
SST: 09950-60020
09951-00730
HINT: Fix the claws of SST to the notches in the differential case assembly.

24. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR






(a) Using SST and a press, remove the dust deflector.
SST: 09950-60010
09951-00380
SST: 09950-70010
09951-07150
SST: 09950-00020
25. DISASSEMBLE DIFFERENTIAL CASE






(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 differential case.






26. 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.