Disassembly

Rear Differential Carrier (1 Of 3):

Rear Differential Carrier (2 Of 3):

Rear Differential Carrier (2 Of 3):

1. w/ Differential lock: Remove indicator switch. Remove the indicator switch and gasket.
2. w/ Differential lock: Remove cover
a. Remove the 3 bolts.
b. Using a brass bar and hammer, tap on the cover to remove it.





3. w/ Differential lock: Remove sleeve.
a. Remove the 4 bolts.
b. Using a plastic hammer, tap the actuator.
c. Remove the actuator and sleeve.





4. w/ Differential lock: Remove actuator and shift fork and shaft.
a. Remove the shift fork shaft bolt.
b. Pull out the actuator and remove the shift fork.





5. Remove companion flange.
a. Using a chisel and hammer, unstake the nut.
b. Using SST 09330-00021 to hold the flange, remove the nut and plate washer.





c. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020), remove the companion flange.





6. Remove oil seal and oil slinger.
a. Using SST 09308-10010, remove the oil seal from the differential carriers;
b. Remove the oil slinger.





7. Remove front bearing. Using SST09556-22010, remove the front bearing from the drive pinion. If the front bearing is damaged or worn, replace the bearing.





8. Remove differential case assembly.

w/o Differential lock:
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 2 adjusting nut locks.

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

c. Remove the 2 bearing caps and adjusting nuts.
d. Remove the differential case with the bearing outer races from the carrier.





w/ Differential lock:
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 4 bolts and 2 bearing caps.





c. Using SST 09504-22011, remove the plate washers.

HINT: Measure the plate washer thickness and note it

d. Remove the differential case with the side bearing outer races from the differential carrier.

HINT: Tag the bearing outer races to show the location for reassembly.

9. Remove drive pinion and bearing spacer from differential carrier.
a. Remove the drive pinion with the rear bearing.
b. Remove the bearing spacer.





10. Remove drive pinion rear bearing.
a. Using SST 09950-00020 and a press, remove the rear bearing from the drive pinion.

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

b. Remove the plate washer from the drive pinion.





11. Remove front and rear bearing outer races. Using a brass bar and hammer, remove the outer races.





12. Remove ring gear.
a. Place matchmarks on the ring gear and differential case.
b. Remove the 12 ring gear set nuts and bolts.
c. Using a plastic hammer, tap on the ring gear to remove it from the differential case.

13. Check differential case runout.
a. Install the differential case in the differential carrier and tighten the adjusting nut just to where there is no play in the bearing.





b. Using a dial indicator, measure the differential case runout.

Maximum case runout: 0.07 mm (0.0028 inch)

c. Remove the differential case.





14. Remove side bearings from differential case.

w/o Differential lock:
^ Using SST09950-40010 (09951-04010, 09952-04010, 09953-04020, 09955-04060, 09957-04010, 09958-04010), 09950-60010 (09951-00480), remove the 2 side bearings from the differential case.

w/ Differential lock:
a. Using SST 09950-40010 (09951-04010, 09952-04010, 6-09953-04020, 09955-04060, 09957-04010, 09958-04010), 09950-60010 (09951-00480), remove the side bearing (ring gear side).

HINT: Fix the claws of SST to the notches in the differential case.





b. Using SST 09550-10012 (09557-10010), 09950-70010 (09951-07150), 4 bolts and a press, remove the side bearing (cover side).

HINT: Fix the claws of SST to the notches in the differential case.





15. Disassemble differential case:

w/o Differential lock:
a. Remove the pinion shaft pin and washer.
b. Remove these parts from the differential case:
^ Pinion shaft.
^ 2 Pinion gears.
^ 2 Pinion gear thrust washers.
^ 2 Side gears.
^ 2 Side gear thrust washers.





w/ Differential lock:
a. Place matchmarks on the case and cover.
b. Using a torx socket wrench, remove the 5 set bolts and 3 pinion shaft pins.





c. Using the 2 cover installation bolts, separate the cover and case.
d. Remove these parts from the differential case:
^ 2 Side gears.
^ 2 Side gear thrust washers.
^ 4 Pinion gears.
^ 4 Pinion thrust washers.
^ 3 Pinion shafts.
^ Pinion shaft holder.

16. Remove dust deflector. Using SST 0995-00020 and a press, remove the dust deflector.
17. Install dust deflector. Using SST 09726-0010 and a press, install a new dust deflector.