Disassembly and Assembly

Disassembly and Assembly

REMOVAL OF DIFFERENTIAL CASE ASSEMBLY





1. Use two 45 mm (1.77 inch) spacers to mount the gear carrier on
Tool number: KV38100800 (J-25604-01)





2. For installation, paint match marks on one side of the bearing caps as shown.

NOTE: Bearing caps are line-bored for initial assembly. Replace the bearing caps in their original positions.





3. Remove the bearing caps.





4. Lift the differential case assembly out of the gear carrier using Tool.
Tool number: HT72400000





^ Keep the side bearing outer races together with the inner races. Do not mix them up.
^ Keep the adjusting washers together with the bearings.

REMOVAL OF DRIVE PINION ASSEMBLY





1. Apply match marks on the companion flange and drive pinion using paint.
2. Loosen the drive pinion nut using Tool as shown.
Tool number: KV40104000
^ Discard the drive pinion nut and use a new drive pinion nut for installation.





3. Remove the drive pinion together with the rear bearing inner race and the bearing adjusting spacer.
4. Remove the front oil seal.
5. Remove the pinion front bearing inner race.
6. Remove the side oil seal.





7. Remove the pinion bearing outer races using a suitable brass drift.





8. Remove the pinion rear bearing inner race and the drive pinion height adjusting washer using Tool.
Tool number:: ST30021000

DISASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY





1. Remove the side bearing inner races using Tools.

CAUTION: To prevent damage to the bearing, engage the puller jaws in the groove.

Tool number A: ST3306S001
B: ST33061000 (J-8107-2)





^ Do not to mix the left and right side parts, clearly label the parts during disassembly.





2. Loosen the drive gear bolts in a cries-cross pattern and remove the bolts.
3. Tap the drive gear off the differential case using a soft hammer.
^ Tap evenly all around the drive gear to keep the drive gear from binding.





4. Drive the pinion mate shaft lock pin out using a suitable punch, from the drive gear side.

INSPECTION

Contact Surfaces
1. Clean the disassembled parts in a suitable solvent and blow dry using compressed air.
2. If the following surfaces are burred or scratched, smooth them using an oil stone.
^ Differential case
^ Side gear
^ Pinion mate gear
^ Pinion mate shaft

Bearing





1. Thoroughly clean the bearing.
2. Check the bearing for wear, scratches, pitting, or flaking.
3. Check the tapered roller bearing for smooth rotation. If damaged, replace the outer race and inner race as a set.

ADJUSTMENT OF DIFFERENTIAL CASE

Thrust Washer Selection





1. Install the side gears, pinion mate gears, and thrust washers into the differential case.





2. Install the pinion mate shaft into the differential case so that it meets the lock pin holes.





3. Adjust the clearance between rear face of side gear and thrust washer by selecting the correct thickness side gear thrust washer. Use two feeler gauges as shown to prevent the side gear from leaning.

Side gear thrust washer and differential case clearance: 0.20 mm (0.0079 inch) or less