1. Differential Carrier Assembly Disassemble

Differential Carrier Assembly Disassemble

Special Tools
* J-22912-01 - Bearing Remover
* J-23907 - Slide Hammer
* J-35405 - Differential Preload Wrench
* J-46002 - Drive Pinion Lock Nut Wrench
* J-46004 - Rear Axle Drive Pinion Holding Tool




1. Using a hexagon wrench (17 mm), remove the rear differential filler plug (1) (inspection plug) and gasket.
2. Remove the stud bolts.




3. Install a dial indicator perpendicular to the inner side of the electromagnetic control coupling subassembly.
4. Rotate the electromagnetic control coupling sub-assembly forward and backward and measure the vertical runout.

Maximum runout - 0.04 mm (0.00157 in)
If the runout is greater than the maximum value, replace the electromagnetic control coupling sub-assembly.




5. Install a dial indicator (1) perpendicular to the electromagnetic control coupling sub-assembly.
6. Rotate the electromagnetic control coupling sub-assembly forward and backward and measure the lateral runout.

Maximum runout - 0.06 mm (0.00236 in)
If the runout is greater than the maximum value, replace the electromagnetic control coupling sub-assembly.




7. Remove the bolts (1, 2, 3, 4) and, using a plastic-faced hammer, lightly tap the electromagnetic control coupling sub-assembly to remove it from the rear differential carrier.




8. Remove the transmission coupling conical spring washer (1) from the differential carrier.




9. Remove the transmission coupling conical spring washer (1) from the differential carrier.




10. Using a screwdriver, remove the rear differential dust deflector.
11. Insert a dial indicator (1) through the rear differential carrier cover plug hole, and set it perpendicular to a ring gear tooth tip.




12. Using J-46004 - Rear Axle Drive Pinion Holding Tool (2), hold the drive pinion in place.

Note: Measure at 3 or more areas around the circumference of the ring gear.

13. Using J-35405 - Differential Preload Wrench , rotate the rear differential case forward and backward, and measure the backlash.

Backlash - 0.10-0.15 mm (0.0039-0.0059 in)
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.





Note: For a more accurate measurement, rotate the case bearing forward and backward before measuring.

14. Using J-46004 - Holding Tool (1) and a torque wrench, inspect the preload (starting torque) within the differential drive pinion and differential ring gear backlash area.

Standard drive pinion preload - 0.4-0.7 Nm (3.0-6.0 lb in)
If the preload is not within the specified range, adjust the total preload or repair as necessary.

Note: For a more accurate measurement, rotate the case bearing forward and backward before measuring.

15. Using J-46004 - Holding Tool and a torque wrench, inspect the preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.

Standard total preload - Standard drive pinion preload plus 0.29-0.49 Nm (2.6-4.3 lb in)
If the preload is not within the specified range, adjust the total preload or repair as necessary.




16. Using J-23907 - Slide Hammer (1), remove the rear differential side gear shaft oil seals from the rear differential carrier.




17. Unstake the rear drive pinion nut using a suitable tool (1).




18. Using J-46004 - Holding Tool (1) and J-46002 - Drive Pinion Lock Nut Wrench (2), hold the differential drive pinion in place and remove the rear drive pinion nut from the differential drive pinion.




19. Using a suitable puller (1), remove the oil diaphragm seal from the rear differential carrier.




20. Remove the rear drive pinion front tapered roller bearing (inner race) from the drive pinion using a suitable tool (1).




21. Remove the differential pressure control hose clips and rear differential pressure control hose.




22. Put matchmarks (1, 2) on the differential pressure control hose elbows and rear differential carrier.
23. Using a screwdriver, remove the differential pressure control hose elbows.




24. Remove the bolts (1-10) from the differential carrier.





Note: Set the brass bar on the ribbed part of the differential side bearing retainer.

25. Using a brass bar and hammer, lightly tap out the differential side bearing retainer from the differential carrier.




26. Using a screwdriver, remove the rear differential carrier cover breather plug from the side bearing retainer.




27. Remove the bolts (1, 2) and rear differential breather plug oil deflector.




28. Remove the rear differential case from the rear differential carrier.




29. Remove the differential drive pinion from the rear differential carrier.




30. Remove the rear differential drive pinion oil slinger from the differential drive pinion.




31. Remove the rear differential drive pinion bearing spacer from the differential drive pinion.





Note: If the rear differential drive pinion or differential ring gear is damaged, replace them both.

32. Using a press and J-22912-01 - Bearing Remover (1), press out the rear drive pinion rear tapered roller bearing (inner race) from the differential drive pinion.
33. Remove the rear differential drive pinion plate washer.




34. Using a suitable puller (1), remove the rear drive pinion front tapered roller bearing (outer race) from the rear differential carrier.





Note: Set the brass bar on the notch (1, 2).

35. Using a brass bar and hammer, lightly and uniformly tap out the rear drive pinion rear tapered roller bearing (outer race) from the differential carrier.




36. Using a press (1), press out the rear differential case bearing right side (outer race) and rear differential side gear shaft plate washer from the rear differential carrier.




37. Using a press (1), press out the rear differential case bearing left side (outer race) and rear differential side gear shaft plate washer from the differential side bearing retainer.
38. Remove the straight pins from the differential carrier.




39. Using a suitable puller (1), remove the rear differential case bearing right side (inner race) from the rear differential case.




40. Using a suitable puller (1), remove the rear differential case bearing left side (inner race) from the rear differential case.




41. Place matchmarks (9) on the rear differential case and differential ring gear.
42. Remove the ring gear bolts (1-11).
43. Using a plastic-faced hammer, lightly tap the outer circumference of the differential ring gear to remove it from the rear differential case.




44. Using a pin punch and a hammer, remove the rear differential pinion shaft pin.
45. Remove the rear differential pinion shaft, differential pinion gears, rear differential pinion thrust washers, differential side gears and rear No. 1 differential side gear thrust washers.




46. Remove the following components from the rear differential case.

1. Differential pinion gear (2)
2. Rear differential pinion thrust washer (1)
3. Rear differential pinion shaft (3)
4. Differential side gear (4)
5. Rear No. 1 differential side gear thrust washer (5)

47. Check the differential pinion gears and differential side gears for wear.
48. Check the differential case for a crack or damage.