Disassembly

Rear Differential

DISASSEMBLY
To detect the real cause of trouble, inspect the following items before disassembling.
^ Tooth contact of crown gear and pinion, and backlash
^ Runout of crown gear at its back surface
^ Turning resistance of drive pinion





1) Set the ST on vise and install the differential assembly to ST.
ST 398217700 ATTACHMENT
2) Drain the gear oil by removing plug.





3) Remove the air breather cap.

NOTE: Do not attempt to replace the air breather cap unless necessary.





4) Remove the rear cover by loosening retaining bolts.





5) Make right and left side bearing retainers in order to identify them at reassembly. Remove the side bearing retainer attaching bolts, set the ST to differential case, and extract right and left side bearing retainers with a puller.

CAUTION: Each shim, which is installed to adjust the side bearing preload, should be kept together with its mating retainer.

ST 398457700 ATTACHMENT





6) Pull out the differential case assembly from differential carrier.

CAUTION: Be careful not to hit the teeth against the case.





7) When replacing the side bearing, pull the bearing cup from side bearing retainer using ST.
ST 398527700 PULLER ASSY





8) Extract the bearing cone with ST.

CAUTION: Do not attempt to disassemble the parts unless necessary.

NOTE:
^ Set the puller so that its claws catch the edge of the bearing cone.
^ Never mix up the right and left hand bearing races and cones.

ST 398527700 PULLER SET





9) Remove the crown gear by loosening crown gear bolts.

CAUTION: Further disassembling is not allowed.





10) Drive out the pinion shaft lock pin from crown gear side. (Without LSD)

NOTE: The lock pin is staked at the pin hole end on the differential carrier; do not drive it out forcibly before unstaking it.

ST 899904100 STRAIGHT PIN REMOVER





11) Draw out the pinion mate shaft and remove pinion mate gears, side gears and thrust washers. (Without LSD)

NOTE: The gears as well as thrust washers should be marked or kept separated right and left, and front and rear.





12) Hold the companion flange with ST and remove drive pinion nut.
ST 498427200 FLANGE WRENCH





13) Extract the companion flange with a puller.





14) Press the end of drive pinion shaft and extract it together with rear bearing cone, preload adjusting spacer and washer.

NOTE: Hold the drive pinion so as not to drop it.

ST3 98467700 DRIFT





15) Remove the rear bearing cone from drive pinion by supporting cone with ST.

NOTE: Place the replacer so that its center-recessed side faces the pinion gear.

ST 398517700 REPLACER





16) Remove the front oil seal from differential carrier using ST.
ST 398527700 PULLER ASSY





17) Remove the pilot bearing together with front bearing cone using ST.
ST 398467700 DRIFT 1





18) When replacing the bearings, tap front bearing cup and rear bearing cup in this order out of case by using a brass bar.