Disassembly and Assembly

DISASSEMBLY
Differential Assembly
1. Remove carrier cover bolts.





2. Separate the carrier cover from the axle housing using Tool.
Tool number: KV10111100 (J-37228)

CAUTION:
^ Be careful not to damage the mating surface.
^ Do not insert flat-bladed screwdriver, this will damage the mating surface.





3. Remove differential sensor connector bolt and differential lock solenoid connector.





4. For proper reinstallation, paint matching mark on one side of side bearing cap.

CAUTION:
^ Side bearing caps are line-board for initial assembly. The matching marks are used to reinstall them in their original positions.
^ For matching mark, use paint. Do not damage side bearing cap.

5. Remove adjuster lock plates.





6. Remove side bearing caps.





7. Remove side bearing adjusters using Tool.
Tool number: - (ST-354-1003)





8. Keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusters together with bearing.
9. Remove side bearing adjusters from axle housing.
10. Remove bracket of differential lock position switch connector and bolts.
11. Remove differential lock Position switch.





12. Remove side bearing inner race and washer using Tool.
Tool number: ST33081000 (-)

CAUTION: Be careful not to damage differential case assembly and differential lock solenoid.

13. Remove differential lock solenoid and solenoid washer.





14. Remove side bearing inner race using Tool.
Tool number: ST33081000 (-)

CAUTION: Be careful not to damage differential case assembly.





15. For proper reinstallation, paint matching mark on differential case assembly and drive gear.

CAUTION: For matching mark, use paint. Do not damage differential case and drive gear.

16. Remove drive gear bolts.
17. Tap drive gear off differential case assembly using suitable tool.

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

Drive Pinion Assembly





1. Remove differential case assembly. Refer to "Differential Assembly".
2. Remove drive pinion nut and washer using Tool.
Tool number: KV40104000 (-)





3. Put a matching mark on the thread edge of drive pinion. The mark should be in line with the mark on companion flange.

CAUTION: For matching mark, use paint. Do not damage drive pinion.





4. Remove companion flange using suitable tool.





5. Remove front oil seal using Tool.
Tool number: ST33290001 (J-34286)

CAUTION: Be careful not to damage axle housing.

6. Remove front bearing thrust washer.





7. Remove drive pinion assembly and collapsible spacer from axle housing, using press.

CAUTION: Do not drop drive pinion assembly.

8. Remove drive pinion front bearing inner race from axle housing.





9. Tap drive pinion front bearing outer race uniformly with a brass bar or equivalent to remove.

CAUTION: Be careful not to damage axle housing.

10. Tap drive pinion rear bearing outer race uniformly with a brass bar or equivalent for removal.

CAUTION: Be careful not to damage axle housing.





11. Remove drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool.
Tool number: ST30021000 (J-22912-01)

ASSEMBLY
Drive Pinion Assembly





1. Press a drive pinion rear bearing outer race into axle housing using Tools.
Tool number
A: ST01500001 (-)
B: ST30022000 (-)

CAUTION: Do not reuse drive pinion rear bearing.





2. Press a drive pinion front bearing outer race into axle housing, using Tool.
Tool number: ST33022000 (-)

CAUTION: Do not reuse drive pinion front bearing.

3. Select drive pinion height adjusting washer. Refer to "Drive Pinion Height Adjusting Washer".





4. Press a drive pinion rear bearing inner race and drive pinion height adjusting washer to drive pinion using Tool.
Tool number: - (C - 4040)

CAUTION: Do not reuse drive pinion rear bearing.

5. Apply gear oil to drive pinion rear bearing and drive pinion front bearing.
6. Install drive pinion front bearing inner race in axle housing.
7. Install front bearing thrust washer to axle housing.





8. Apply multi-purpose grease to front oil seal lip. Install front oil seal into axle housing using Tool.
Tool number: ST15310000 (-)

CAUTION:
^ Do not reuse oil seal.
^ When installing, do not incline oil seal.





9. Install collapsible spacer to drive pinion. And then install drive pinion assembly in axle housing.

CAUTION:
^ Do not reuse collapsible spacer.
^ Be careful not to damage front oil seal.





10. Align the matching mark of drive pinion with the mark of companion flange.





11. Install companion flange onto drive pinion. Tap companion flange until fully seated using suitable tool.

CAUTION: Be careful not to damage companion flange and front oil seal.





12. Install drive pinion nut and drive pinion nut washer. Tighten drive pinion nut until total preload is within specification using Tool.
^ The threaded portion of drive pinion and drive pinion nut should be free from oil or grease.
Tool number: KV40104000 (-)

CAUTION: Do not reuse drive pinion nut and drive pinion nut washer.





13. Tighten drive pinion nut by very small degrees until the specified preload is achieved. When checking the preload, turn drive pinion in both directions several times to set the bearing rollers, using Tool.
Tool number: ST3127S000 (J-25765-A)
Pinion bearing preload: 1.7 - 3.1 Nm (0.18 - 0.31 kg-m, 15 - 27 inch lbs.)
a. This procedure will have to be repeated if:
^ Maximum preload is achieved before the minimum drive pinion nut torque is reached.
^ Minimum preload is not achieved before maximum drive pinion nut torque is reached.

Differential Assembly





1. Align the matching mark of differential case assembly with the mark of drive gear, then install drive gear.





2. Apply thread locking sealant into the thread hole of drive gear.
^ Use Genuine Medium Strength Thread Locking Sealant or equivalent. Refer to "Recommended Chemical Products and Sealants".

CAUTION: Make sure the drive gear back and threaded holes are clean.





3. Install the drive gear bolts, and then tighten to the specified torque. Refer to "COMPONENTS".

CAUTION:
^ Do not reuse the bolts.
^ Tighten bolts in a crisscross fashion.





4. Press side bearing inner races to differential case assembly using Tool.
Tool number: ST33081000 (-)

CAUTION: Do not reuse side bearing.





5. Install differential lock solenoid and washer.
6. Press side bearing inner races to differential case assembly using Tools.
Tool number
A: KV38100300 (J-25523)
B: ST33081000 (-)
7. Apply sealant to threads of differential lock position switch.
^ Use Genuine Silicone RTV or equivalent. Refer to "Recommended Chemical Products and Sealants".

CAUTION: Remove old sealant adhering to axle housing and differential lock position switch. Also remove any moisture, oil, or foreign material adhering to application and axle housing and differential lock position switch.





8. Install differential lock position switch on axle housing and tighten differential lock position switch bolts with the specified torque. Refer to "COMPONENTS".





9. Install side bearing adjusters into axle housing.





10. Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into axle housing.
11. Apply multi-purpose grease to sensor connector.

CAUTION: Do not reuse sensor connector.





12. Connect differential lock solenoid harness and sensor connector. Then install it to axle housing, tighten to the specified torque. Refer to "COMPONENTS".





13. Align paint matching mark on side bearing caps with that on axle housing and install side bearing caps on axle housing.

CAUTION: Do not tighten at this point. This allows further tightening of side bearing adjusters.





14. Tighten each side bearing adjusters using Tool.
Tool number: - (ST-354-1003)
15. Adjusting backlash of drive gear and drive pinion. Refer to "Backlash".
16. Check total preload. Refer to "Total Preload Torque".
17. Check tooth contact. Refer to "Tooth Contact".





18. Apply sealant to mating surface of carrier cover.
^ Use Genuine Silicone RTV or equivalent. Refer to "Recommended Chemical Products and Sealants".

CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating surfaces.

19. Install carrier cover on axle housing and tighten carrier cover bolts with the specified torque. Refer to "COMPONENTS".