Assembly

DISASSEMBLY OF DIFFERENTIAL

1. REMOVE ACTUATOR

(a) Remove the four bolts.
(b) Using a hammer, remove the actuator.

2. REMOVE DIFFERENTIAL CARRIER COVER

Remove the eight bolts and tap off the cover with a plastic-faced hammer.

3. 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.

4. REMOVE LH SIDE GEAR SHAFT WITH TUBE

(a) Remove the four torx bolts.

Torx wrench: E14 (Part No. 09044-00010 or locally manufactured tool)

(b) Using a plastic-faced hammer, tap on the tube to remove it.

(a) Remove the two torx bolts.

Torx wrench: E14 (Part No. 09044-00010 or locally manufactured tool)

(b) Using a plastic-faced hammer, tap on the clutch case to remove it.

6. REMOVE RH SIDE GEAR SHAFT

Using SST, pull off the RH side gear shaft. SST 09910-00015 (09911-00011, 09912-00010, 09914-000111)

7. REMOVE INTERMEDIATE SHAFT

Using SST, pull off the intermediate shaft. SST 09350-20015 (09369-20040), 09950-20017

8. REMOVE RH SIDE OIL SEAL

Using SST, remove the oil seal. SST 09308-00010

9. CHECK RING GEAR RUNOUT

Using a dial indicator, measure the ring gear runout.

Maximum runout: 0.07 mm (0.0028 in.)

If the runout is greater than maximum, replace the ring gear and drive pinion as a set.

10. CHECK RING GEAR BACKLASH

(a) Fix the dial indicator on the tooth surface at a 90 angle.
(b) Holding the drive pinion flange, measure the ring gear backlash.

Ring gear backlash: 0.13-0.18 mm (0.0051 - 0.0071 in.)

If the backlash is not within specification, adjust the ring gear backlash.

HINT:
Measure from three or more places on the circumference of the ring gear.

11. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

12. MEASURE DRIVE PINION PRELOAD

Using a torque gauge, measure the preload of the backlash between the drive pinion and ring gear.

Preload (starting): 6 - 10kg-cm (5.2 - 8.7 in-lb, 0.6 - 1.0 N~m)

13. CHECK TOTAL PRELOAD

Using a torque gauge, measure the total preload.

Total preload (starting): Add drive pinion preload 4 - 6 kg-cm (3.5 - 5.2 in.-lb, 0.4 - 0.6 N~m)

14. REMOVE COMPANION FLANGE

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

(b) Using SSI to hold the flange remove the nut. SST 09330-00021

(a) Using SST, remove the oil seal from the housing. SST 09308-10010

(b) Remove the oil slinger.

16.REMOVE REAR BEARING AND BEARING SPACER

(a) Using SST, remove the rear bearing from drive pinion. SST 09556-30010

(b) Remove the bearing spacer. If the rear bearing is damaged or worn, replace the bearing.

17. REMOVE DIFFERENTIAL CASE AND RING GEAR

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

(c) Using SST and a hammer, remove the two side bearing preload adjusting plate washers. SST 09504-22011

HINT:
Measure the adjusting plate washer and note the thickness.

(d) Remove the differential case with bearing outer race from the carrier.

HINT:
Tag the bearing outer races to show the location for reassembly.

18.REMOVE DRIVE PINION FROM DIFFERENTIAL CARRIER