Disassembly

INSPECTION OF DIFFERENTIAL CARRIER

1. CHECK RUNOUT OF COMPANION FLANGE
Using a dial indicator, measure the vertical and lateral runout of the companion flange.

Maximum vertical runout: 0.10 mm (0.0039 in.)

Maximum lateral runout: 0.10 mm (0.0039 in.)

If the runout is greater than the maximum, replace the companion flange.

2. CHECK RING GEAR RUNOUT
If the runout is greater than maximum, replace the ring gear.

Maximum runout: 0.10 mm (0.0039 in.)

3. CHECK RING GEAR BACKLASH
If the backlash is not within specification, adjust the side bearing preload or repair as necessary.

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)

HINT: Perform the measurements at three or more positions around the circumference of the ring gear.

4. MEASURE DRIVE PINION PRELOAD
Measure the drive pinion preload using the backlash of the drive pinion and ring gear.

Preload (at starting): 5 - 8 kg.cm. (4.3 - 6.9 in.lb, 0.5 - 0.8 N.m.)

5. CHECK TOTAL PRELOAD
Using a torque meter, measure the total preload.

Total preload: (In addition to drive pinion preload): 4 - 6 kg.cm. (3.5 - 5.2 in.lb, 0.4 - 0.6 N.m.)

If necessary, disassemble and inspect a differential.

6. CHECK SIDE GEAR BACKLASH
Measure the side gear backlash while holding one pinion gear toward the case.

Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)

If the backlash is out of specification, install the correct thrust washers.

7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

DISASSEMBLY OF DIFFERENTIAL CARRIER
1. REMOVE COMPANION FLANGE

(a) Using a hammer and chisel, loosen the staked part of the nut.

(b) Using SST to hold the flange, remove the nut and plate washer.
SST 09330-00021

2. REMOVE REAR OIL SEAL AND OIL SLINGER
(a) Using SST, remove the oil seal from the housing.
SST 09308-10010
(b) Remove the oil slinger.

3. REMOVE REAR BEARING
Using SST, remove the bearing from the housing.
SST 09556-22010

4. REMOVE DIFFERENTIAL CASE

(a) Place matchmarks on the bearing cap and differential carrier.
(b) Remove the two adjusting nut locks.

(e) Remove the differential case with the side bearing outer races from the differential carrier.

HINT: Tag the disassembled parts to show the location for reassemble.

5. REMOVE DRIVE PINION AND BEARING SPACER
(a) Remove the drive pinion with the front bearing.
(b) Remove the bearing spacer.

6. REMOVE DRIVE PINION FRONT BEARING
(a) Using SST and a press, remove the bearing from the drive pinion.
SST 09950-00020

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

(b) Remove the plate washer from the drive pinion.

7. REMOVE FRONT, REAR BEARING OUTER RACES AND OIL STORAGE RING

(a) Using SST, remove the bearing outer race.
SST 09308-00010

(b) Using a hammer and brass bar, drive out the oil storage ring and outer race from the carrier.

HINT: Do not remove the oil storage ring unless replacing it with a new one.

8. REMOVE RING GEAR

(a) Using a screwdriver, unstake the lock plates.

(b) Place matchmarks on the ring gear and differential case.
(c) Remove the ten bolts and five lock plates.

(d) Using a plastic or copper hammer, tap on the ring gear to separate it from the differential case.

9. CHECK DIFFERENTIAL CASE RUNOUT
(a) Place the bearing outer races on their respective bearings. Check that the left and right outer races are not interchanged.
(b) Install the differential case in the differential carrier.
(c) When there is no play left in the side bearings, install the adjusting nuts.
(d) Align the matchmarks on the bearing cap and differ ential carrier.
(e) Install and uniformly tighten the four bearing cap bolts in several passes.
(f) Using a dial indicator, measure the differential case runout.

Maximum runout: 0.07 mm (0.0028 in.)

(g) Remove the differential case.

10. REMOVE SIDE BEARING
Using SST, remove the side bearing from the differential case.
SST 09950-20017

HINT: Fix the claws of SST to the notch in the differential case.

11. DISASSEMBLE DIFFERENTIAL CASE

(a) Using a hammer and punch, drive out the straight pin.

(b) Remove following parts from the differential case:
(1) Pinion shaft
(2) Two differential pinions
(3) Two pinion thrust washers
(4) Two side gears
(5) Two side gear thrust washers

REPLACEMENT OF DUST DEFLECTOR
1. REPLACE COMPANION FLANGE DUST DEFLECTOR

(a) Using SST and a press, remove the dust deflector.
SST 09950-00020

(b) Using SST and a press, install a new dust deflector.
SST 09726-40010