Disassembly

1. Check runout of companion flange.
Using a dial indicator, measure the runout of the companion flange vertical and lateral.
Maximum:
Vertical runout: 0.09 mm (0.0035 inch)
Lateral runout: 0.09 mm (0.0035 inch)
If the runout is greater that the maximum, replace the companion flange.





2. Check ring gear runout.
Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 inch)





3. Check ring gear runout.
Using a dial indicator, measure the ring gear backlash.
Backlash:
2WD: 0.08-0.13 mm (0.0031-0.0051 inch)
4WD: 0.13-0.18 mm (0.0051-0.0071 inch)
If the backlash in not within specification, adjust the side bearing preload or repair if necessary.

HINT: Measure from 3 or more places on the circumference of the ring gear.

4. Check tooth contact between ring gear and drive pinion.





5. Check side gear backlash.
Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the case.
Backlash: 0.05-0.20 mm (0.0020-0.0079 inch)
If the backlash is not within specification, install the side gear thrust washers of differential thickness.
6. Remove companion flange.
a. Using a chisel and hammer, unstake the staked part of the nut.





b. Using Special Service Tool (SST) 09330-00021 or equivalent, to hold the flange, remove the nut.





c. Using SST 09950-30010 or equivalent, remove the companion flange.





7. Remove front oil seal.
Using SST 09308-10010 or equivalent,remove the oil seal from the differential carrier.
8. Remove front bearing and bearing spacer.





a. Using SST 09556-22010 or equivalent, remove the bearing from the drive pinion.
b. Remove the two washers and bearing spacer. If the front bearing is damaged or worn, replace the bearing.
9. Remove differential case.





a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the four bolts and bearing cap.





c. Using SST 09504-22011 or equivalent, and a hammer, remove the two side bearing plate washers.

HINT: Measure the plate washer and note the thickness.

d. Remove the differential case and bearing outer race from the carrier.

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

10. Remove drive pinion from differential carrier.





11. Remove drive pinion rear bearing.
Using SST 09950-00020 or equivalent, 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.





12. Remove front and rear bearing outer races.

NOTICE: Do not remove the outer races except when replacing the bearings.

Using a brass bar and hammer, remove the two outer races and adjusting washer from the carrier.

HINT: Measure the adjusting washer and note the thickness.

13. Remove ring gear.





a. Place matchmarks on the ring gear and differential case.
b. Remove the 12 ring gear set bolts.
c. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
14. Check differential case runout.
a. Install the differential case in the differential carrier.





b. Using a dial indicator, measure the differential case runout.
Maximum case runout: 0.04 mm (0.0016 inch).
c. Remove the differential case.





15. Remove side bearings.
Using SST 09950-40010, 09950-60010 (09951-00450) or equivalents, remove the two side bearings from the differential case.

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

16. Disassemble differential case assembly.





a. Using a pin punch and hammer, remove the straight pin.
b. Remove these parts from the differential case:
- Pinion shaft
- Two pinion gears
- Two pinion gear thrust washers
- Two side gears
- Two side gear thrust washers