Disassembly

DIFFERENTIAL ASSEMBLY


2WD : Disassembly

1. Drain gear oil, if necessary.
2. Remove side flange.
3. Remove rear cover mounting bolts.





4. Remove rear cover to insert the seal cutter (A) [SST:
KV10111100 (J-37228)] between gear carrier and rear cover.

CAUTION:
- Never damage the mating surface.
- Never insert flat-bladed screwdriver, this may damage the mating surface.





5. Using two 45 mm (1.77 in) spacers, mount carrier on the attachment (A) [SST: KV38100800 (J-25604-01)].





6. For proper reinstallation, paint matching marks on one side of the bearing cap.

CAUTION:
- For matching marks, use paint. Never damage bearing caps and gear carrier.
- Bearing caps are manufactured as integral molding. Use the matching marks to them in their original positions.





7. Remove bearing caps.





8. Lift differential case assembly out with a sliding hammer (commercial service tool).





- Keep side bearing outer races together with inner race. Never mix them up.
Also, keep side bearing adjusting washers together with bearings.





9. Remove side bearing inner race with puller (A) and base (B).
To prevent damage to bearing, engage puller jaws in groove
( ).

A : Puller [SST: ST33051001 (J-22888-20)]
B : Base [SST: ST33061000 (J-8107-2)]

CAUTION:
- To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
- It is not necessary to remove side bearing inner race except when it is replaced.





10. For proper reinstallation, paint matching marks on one differential case assembly.

CAUTION:
For matching marks, use paint. Never damage differential case and drive gear.
11. Remove drive gear mounting bolts.
12. Tap drive gear off differential case assembly with a soft hammer.

CAUTION:
Tap evenly all around to keep drive gear from bending.





13. Remove lock pin of pinion mate shaft with a punch from drive gear side.





14. Remove pinion mate shaft.





15. Turn pinion mate gear, then remove pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from differential case.
16. Remove circular clip from side gear.

CAUTION:
Never damage side gear.