Part 2

OVERHAUL (CONTINUED)





31. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION
a. Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 inch) away from the end of the shaft.
Maximum runout: 0.08 mm (0.0031 inch)
If the runout is greater than the maximum, replace the drive pinion and ring gear.





32. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Using SST and a torque wrench, measure the preload of backlash between the drive pinion and ring gear.
SST 09229-55010
Preload (at starting): 0.5 to 0.8 Nm (5 to 8 kgf-cm, 4.3 to 6.9 inch lbs.)
If the preload is not within the specification, adjust the rear differential drive pinion preload or repair as necessary.





33. INSPECT TOTAL PRELOAD
a. Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
SST 09229-55010
Total preload (at starting):
Drive pinion preload plus 0.46 to 1.37 Nm (4.69 to 13.97 kgf-cm, 4.07 to 12.13 inch lbs.)
If necessary, disassemble and inspect the differential.





34. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY
a. Using SST, tap out the 2 shafts.
SST 09910-00015 (09911-00011, 09912-00010, 09914-00011)

NOTICE: Be careful not to damage the oil seal.





35. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
a. Using a screwdriver, pry out the snap ring.





36. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT DUST COVER
a. Using screwdriver and hammer, tap out the dust cover.

NOTICE: Be careful not to damage the rear differential side gear shaft.





37. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST, tap out the 2 oil seals.
SST 09308-00010





38. Except ring gear side position: REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
a. Install SST to the rear differential carrier.
SST 09571-50010





b. Install a dial indicator to the rear differential carrier assembly.
c. Tighten SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.004 inch) clearance between the side bearing (outer race) and side gear shaft snap ring.

NOTICE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.0008 inch).

HINT:
^ Set the dial indicator to the rearmost position (upper side in the illustration) of the area where the side gear shaft oil seal is tapped inch)
^ Approximately 0.1 mm (0.004 inch) clearance between the side bearing (outer race) and the side gear shaft snap ring is sufficient for the washer to move slightly.





d. Using snap ring pliers, remove the snap ring on the drive pinion side.

HINT: For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result.

e. Remove the dial indicator and loosen the SST bolt.

NOTICE: Do not remove SST.





39. Ring gear side position: REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
a. Using SST and a hammer, create a clearance between the side bearing (outer) on the ring gear and side gear shaft snap ring.
SST 09608-32010, 09950-70010 (09951-07200)

HINT: The clearance cannot be seen, but tapping SST with a hammer three or four times should be enough.





b. Using snap ring pliers, remove the snap ring on the ring gear side.

HINT: For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result.





40. Ring gear side position: REMOVE REAR DIFFERENTIAL CASE BEARING
a. Tighten the SST bolt and push out the outer race on the ring gear side.
SST 09571-50010

NOTICE: Do not drop the side bearing (outer race).

b. Remove SST.





41. Except ring gear side position: REMOVE REAR DIFFERENTIAL CASE BEARING
a. Raise the ring gear of the differential case slightly to remove the drive pinion side outer race.

HINT: For reassembly, check the installation position of the outer race and the side gear shaft snap ring before removing the outer race. Write down the result.





42. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY

NOTICE: Be careful not to damage the case bearing.





43. REMOVE REAR DRIVE PINION NUT
a. Using a chisel and hammer, loosen the staked part of the nut.





b. Using SST to hold the drive pinion companion flange, remove the nut.
SST 09229-55010, 09950-30012 (09955-03040), 09330-00021 (09330-00030)





44. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060)





45. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
46. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Using a magnet hand, remove the differential drive pinion oil slinger.





47. REMOVE DIFFERENTIAL DRIVE PINION
a. Using a press, press out the drive pinion with the rear bearing from the differential carrier.

NOTICE: Be careful not to drop the drive pinion.





48. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Remove the spacer from the drive pinion.





49. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Remove the front bearing from the differential carrier.





b. Using a brass bar and hammer, tap out the front bearing outer race.





50. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, press out the rear bearing from the drive pinion.
SST 09950-00020

NOTICE: Do not drop the drive pinion.

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





b. Using a brass bar and hammer, tap out the rear bearing outer race.
c. Remove the plate washer.





51. REMOVE DIFFERENTIAL RING GEAR
a. Place matchmarks on the ring gear and differential case.





b. Remove the 10 ring gear set bolts.





c. Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.





52. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSY
a. Install the differential case as shown in the illustration.

HINT: If the ring gear runout is within the specified value (see step 27), this inspection is not necessary.

NOTICE: Do not damage the case bearing.





b. Using SST and a hammer, tap in the outer race on the drive pinion side.
SST 09608-32010, 09950-70010 (09951-07200)

HINT: Tap in the outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.





c. Place SST on the differential carrier.
SST 09571-50010
d. Tighten the SST bolt until the SST disc lightly touches the case bearing (outer race).





e. Using SST and a hammer, tap in the outer race on the ring gear side.
SST 09950-70010 (09951-07200), 09608-32010

HINT: Tap in the outer race until it touches the case bearing roller.

f. Place a dial indicator on the differential case flange surface at a right angle.





g. Using a dial indicator, measure the differential case run out.
Maximum runout: 0.05 mm (0.0020 inch)
If the runout is greater than the maximum, replace the rear differential case sub-assembly with a new one.





53. Ring gear side position: REMOVE REAR DIFFERENTIAL CASE BEARING
a. Tighten the SST bolt to push out the ring gear side outer race.
SST 09571-50010

NOTICE: Do not drop the side bearing (outer race).

b. Remove SST.





54. Except ring gear side position: REMOVE REAR DIFFERENTIAL CASE BEARING
a. Raise the ring gear side of the differential case slightly to remove the drive pinion side outer race.





55. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY

NOTICE: Be careful not to damage the side bearing.





56. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the 2 differential case bearings from the differential case.
SST 09950-60010 (09951-00480), 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)

HINT: Do not remove the case bearing when not replacing the differential case.

NOTICE:
^ Do not deform the bearing case.
^ Hook the claws of SST to the bearing inner race of the differential case.





57. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, press out the dust deflector.
SST 09950-60010 (09951-00440), 09950-00020, 09950-70010 (09951-07100)

NOTICE: Do not drop the differential carrier.





58. INSPECT DIFFERENTIAL PINION GEAR BACKLASH
a. Using a vise, hold the differential case between 2 aluminum plates.
b. Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0 mm (0 inch).
If the backlash is not as specified, replace the rear differential case sub-assembly with a new one.





59. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

HINT: Perform this procedure only when replacing the dust cover.

a. Using SST and a press, press a new dust deflector into the companion flange.
SST 09316-60011 (09316-00011)

NOTICE:
^ Slowly press a new dust deflector into the companion flange while observing the dust deflector. Do not press excessively.
^ If necessary, remove any burrs after inserting the new dust deflector.





60. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear in boiling water that is approximately 100°C (212°F).
c. Carefully take the ring gear out of the boiling water.





d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

HINT: Align the matchmarks on the ring gear and the differential case.

e. Tighten the new 2 bolts temporarily so that the bolt holes in the ring gear and differential case are not misaligned.

NOTICE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently.