Disassembly

Differential Carrier (3RZ-FE, 5VZ-FE w/Differential Lock):

DISASSEMBLY
1. Remove actuator.
a. Remove the bolt and actuator from the differential carrier.
b. Remove the O-ring.





2. Remove indicator switch. Remove the indicator switch and gasket.





3. Remove shift fork shaft.
a. Using a hexagon wrench, remove the 2 straight screw plugs.
b. Remove the spring seat, spring and steel ball.





c. Using a pin punch and a hammer, remove the slotted spring pin.
d. Remove the 2 bolts from the shaft retainer.





e. Using a plastic hammer, remove the shaft retainer.
f. Remove the shift fork shaft.

HINT: Pull out the shift fork shaft with a screwdriver turned round.

4. Remove companion flange
a. Using a chisel and a hammer, unstake the nut.





b. Using SST 09330-00021 to hold the flange, remove the nut.





c. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020), remove the companion flange.





5. Remove oil seal and oil slinger.
a. Using SST 09308-10010, remove the oil seal from the differential carrier.
b. Remove the oil slinger.





6. Remove front bearing. Using SST 09556-22010, remove the front bearing from the drive pinion.





7. Remove differential case.
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 2 adjusting nut locks.
c. Remove the 4 bolts and 2 bearing caps.





d. Remove the differential case with side bearing outer race, adjusting nuts and sleeve from the differential carrier.
e. Remove the shift fork.

8. Remove drive pinion and bearing spacer.
a. Remove the drive pinion with the rear bearing.
b. Remove the bearing spacer.





9. Remove drive pinion rear bearing.
a. Using SST 09950-00020 and a press, remove the bearing from the drive pinion.

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

b. Remove the plate washer from the drive pinion.





10. Remove front and rear bearing outer races and oil strange ring.
a. Using SST 09308-00010, remove the front bearing outer race.
b. Using a brass bar and a hammer, remove the oil storage ring
c. Using a brass bar and a hammer, remove the bearing.





11. Remove ring gear.
a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver and a hammer, unstake the lock plate.
c. Remove the ring gear set bolts and lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.

12. Check differential case runout.
a. Install the differential case in the differential carrier and tighten the adjusting nut just to where there is no play in the bearing.





b. Using a dial indicator, measure the differential case runout.

Maximum case runout: 0.07 mm (0.0028 inch)

c. Remove the differential case.





13. Remove side bearing from differential case. Using SST 09950-40010 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04060, 09957-04010, 09958-04010), 09950-60010 (09951-00480), 09950-60020 (09951-00730), remove the side bearing from the differential case.

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





14. Disassemble differential case.
a. Place matchmarks on the LH and RH cases.
b. Remove the 8 bolts uniformly, a little at a time.
c. Using a plastic hammer, separate the LH and RH cases. Remove these parts from the differential case:
^ 2 side gear
^ 2 side gear thrust washer
^ Spider
^ 4 pinion gear
^ 4 pinion gear thrust washer





15. Inspect sleeve.
a. Install the sleeve to the differential case (LH) and check it moves smoothly.
b. Install the sleeve to the side gear and check it moves smoothly.





16. Measure clearance of shift fork and sleeve. Using a feeler gauge, measure the clearance between the shift fork and sleeve.

Clearance (Reference): 0.15 - 0.35 mm (0.006 - 0.014 inch)