Disassembly and Assembly

DISASSEMBLY
Differential Assembly





1. Remove carrier cover bolts.
2. Separate carrier cover from 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. 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.

4. Remove adjuster lock plates.





5. Remove side bearing caps.





6. Remove side bearing adjusters using Tool.
Tool number: - (ST-3541003)





7. Keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusters together with bearing.
8. Remove side bearing adjusters from axle housing.





9. Remove side bearing inner races using Tool.
Tool number: ST33081000 (-)

CAUTION: Be careful not to damage differential case.





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

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

11. Remove drive gear bolts.
12. Tap drive gear off differential case using suitable tool.

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





13. Pull lock pin out of pinion mate shaft, using Tool.
Tool number: ST23550000 (-)





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.

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. Press the drive pinion assembly and collapsible spacer from axle housing.

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 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 the drive pinion nut using Tool until total preload is within specification.
^ 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 It torque is reached.
^ Minimum preload is not achieved before maximum drive pinion nut torque is reached.

Differential Assembly





1. Assemble side gear thrust washers with the same thickness as the ones installed prior to disassembly or reinstall the old ones on side gears.
2. Assemble side gear and side gear thrust washer into differential case.





3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and assemble them into differential case after assembling pinion mate thrust washer to pinion mate gear.





4. Align lock pin holes on differential case and shaft, and assemble pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to "Side Gear Thrust Washer".





6. Drive a lock pin into pinion mate shaft, using Tool.
Tool number: ST23550000 (-)

CAUTION: Do not reuse lock pin.





7. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly.





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





9. 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.





10. 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.





11. Press side bearing inner races to differential case using Tools.
Tool number
A: KV38100300 (J-25523)
B: ST33081000 (-)

CAUTION: Do not reuse side bearing.





12. Install side bearing adjusters into axle housing.





13. Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into axle housing.





14. 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.





15. Tighten each side bearing adjuster using Tool.
Tool number: - (ST-3541003)
16. Adjust backlash of drive gear and drive pinion. Refer to "Backlash".
17. Check total preload. Refer to "Total Preload Torque".
18. Check tooth contact. Refer to "Tooth Contact".





19. 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.

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