Disassembly

DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY (w/ Differential Lock):

DISASSEMBLY

1. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY
(a) Fix the rear differential carrier assembly to the overattachment.

2. INSPECT REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
(a) Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
Maximum runout:
Vertical runout: 0.10 mm (0.0039 in.)
Lateral runout: 0.10 mm (0.0039 in.)
If the runouts are not with the specifications, replace the companion flange.

3. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
(a) Using a dial indicator, check the runout of the ring gear.
Maximum runout:
0.07 mm (0.0028 in.)
If the runout is greater than the maximum, replace the ring gear with a new one.

4. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Using a dial indicator, check the backlash of the ring gear.
Backlash:
0.13 to 0.18 mm (0.0051 to 0.0071 in.)
If the backlash is not within the specification, adjust or repair the side bearing preload as necessary.

5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
Preload (at starting):
0.56 to 0.85 N*m (5.7 to 8.7 kgf*cm, 5.0 to 7.5 in.*lbf)
If necessary, disassemble and inspect the differential assembly.

6. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
(b) Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus 0.39 to 0.59 N*m (4.0 to 6.0 kgf*cm, 3.5 to 5.2 in.*lbf)
If necessary, disassemble and inspect the differential.

7. REMOVE DIFFERENTIAL LOCK SHIFT ACTUATOR
(a) Remove the 4 bolts and actuator from the differential carrier.
(b) Remove the O-ring.

8. REMOVE NO.1 TRANSFER INDICATOR SWITCH
(a) Remove the indicator switch and gasket.
9. REMOVE REAR DIFFERENTIAL LOCK SHIFT FORK SHAFT

(a) Using a 6 mm hexagon wrench, remove the 2 screw plugs.
(b) Remove the spring seat, spring and ball.

(d) Remove the 2 bolts from the shaft retainer.
(e) Using a plastic hammer, remove the shaft retainer.
(f) Remove the shift fork shaft.
10. REMOVE REAR DRIVE PINION NUT

(a) Using SST and a hammer, loosen the staked part of the nut.
SST: 09930-00010

(b) Using SST to hold the drive pinion companion flange, remove the nut.
SST: 09330-00021

11. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
(a) Using SST, remove the drive pinion companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03030

12. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
(a) Using SST and a press, remove the dust deflector.
SST: 09950-60010
09951-00380
SST: 09950-70010
09951-07150
SST: 09950-00020

13. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST, remove the oil seal from the differential carrier.
SST: 09308-10010
14. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

15. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST, remove the drive pinion tapered roller bearing from the drive pinion.
SST: 09556-22010

16. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK
(a) Remove the 2 bolts and 2 rear differential bearing adjusting nut locks.
17. REMOVE DIFFERENTIAL CASE ASSEMBLY

(a) Place matchmarks on the bearing cap and differential carrier.
(b) Remove the 4 bolts and 2 differential bearing caps.
(c) Remove the 2 adjusting nuts.

(d) Remove the rear differential case sub-assembly and 2 case bearings from the differential carrier.
HINT: Tag the 2 case bearings outer races to show the locations for reassembly.

18. REMOVE DIFFERENTIAL DRIVE PINION
(a) Remove the differential drive pinion and bearing spacer from the differential carrier.

19. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST and a press, remove the drive pinion tapered roller bearing from the drive pinion.
SST: 09950-00020
HINT: If either the drive pinion or ring gear is damaged, replace them as a set.

20. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

21. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST, remove the front tapered roller bearing from the carrier.
SST: 09308-00010
(b) Using a brass bar and a hammer, remove the oil storage ring from the carrier.

22. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using a brass bar and a hammer, remove the rear tapered roller bearing from the carrier.
23. REMOVE DIFFERENTIAL RING GEAR

(a) Place matchmarks on the ring gear and differential case.
(b) Using a screwdriver and a hammer, unstake the lock plates.
(c) Remove the 10 ring gear set bolts and 5 lock plates.

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

24. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT
(a) Install the rear differential case bearing onto the differential case.
(b) Install the differential case onto the differential carrier.
(c) Install the 2 bearing caps and 4 bolts onto the differential carrier.
Torque: 85 Nm (870 kgf-cm, 63 ft-lbf)
(d) Inspect the differential case runout.
Maximum runout:
0.07 mm (0.0028 in.)
(e) Remove the differential case.
(f) Remove the rear differential case bearing.

25. REMOVE REAR DIFFERENTIAL CASE BEARING
(a) Using SST, remove the 2 rear differential case bearings from the differential case.
SST: 09950-40011
09951-04020
09952-04010
09953-04030
09954-04010
09955-04061
09957-04010
09958-04011
SST: 09950-60010
09951-00360
26. DISASSEMBLE DIFFERENTIAL CASE

(a) Place matchmarks on the LH and RH cases.
(b) Remove the 8 bolts.

(d) Remove these parts from the differential case.

27. INSPECT REAR DIFFERENTIAL LOCK SLEEVE

(a) Install the sleeve onto the differential case (LH) and check that it moves smoothly.
(b) Install the side gear onto the sleeve and check that it moves smoothly.

(c) Using a feeler gauge, measure the clearance between the shift fork and sleeve.
Maximum clearance:
0.15 to 0.35 mm ( 0.0059 to 0.0138 in.)
28. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
(a) Check that there is no damage to the differential pinion and differential side gear.
If the differential pinion and/or differential side gear is damaged, replace the differential.
29. INSPECT DIFFERENTIAL CASE ASSEMBLY
(a) Check that the differential case is not damaged.
If the differential case is damaged, replace the differential case.