AXLE AND DIFFERENTIAL  REAR DIFFERENTIAL CARRIER ASSEMBLY(for Torque Vectoring Differential)  DISASSEMBLY  

3.271,3.229 3.427,3.427 0.156,0.198 10 false -

	Connector
	Breather Tube
	Bolt

Disconnect the 6 connectors and 2 breather tubes.

Disengage the 3 clamps.

Remove the 4 bolts and differential disconnect cover from the torque vectoring differential carrier assembly.

Remove the 4 bolts and No. 2 differential disconnect cover from the torque vectoring differential carrier assembly.

0.25,0.167 0.75,0.5 0.5,0.333 10 false *a 2.083,0.167 2.583,0.5 0.5,0.333 10 false *b 3.021,1.802 3.292,2.031 0.271,0.229 10 true *c

*a	Vertical Runout
*b	Lateral Runout
*c	30 mm (1.18 in.)

Using a dial indicator, measure the runout of the rear drive pinion companion flange vertical runout and lateral runout.

Maximum Runout:

Item	Specified Condition
Vertical runout	0.1 mm (0.00394 in.)
Lateral runout	0.1 mm (0.00394 in.)

NOTICE:

Measure the runout of the rear drive pinion companion flange horizontally at a position 50 mm (1.97 in.) away from the center of the differential drive pinion shaft.

HINT:

If the runout is more than the maximum value, replace the rear differential carrier assembly.

Using a torque wrench, check the starting torque (total preload) with the teeth of the drive pinion and ring gear in contact.

HINT:

·

The torque wrench should be installed as shown in the illustration.

·

Record the measured value as it is used during assembly.

·

For a more accurate measurement, rotate the bearing forward and backward several times before the measurement.

1.698,1.375 2.5,1.167 2.5,1.167 2.667,1.167 false 2.75,1.083 3.208,1.281 0.458,0.198 10 false SST

Using a SST and hammer, unstake the rear drive pinion nut.

SST

09930-00010  (09931-00010, 09931-00020)

NOTICE:

·

Completely unstake the rear drive pinion nut.

·

Do not damage the threads of the differential gear.

1.802,1.729 1.802,2.333 1.802,2.333 2.833,2.333 true 2.125,1.833 2.125,2.333 true 2.521,1 2.833,1.156 0.313,0.156 10 false *a 0.854,0.51 1.167,0.667 0.313,0.156 10 false *b 2.875,2.26 3.302,2.479 0.427,0.219 10 false SST

*a	Turn
*b	Hold

Using SST, remove the rear drive pinion companion flange sub-assembly.

SST

09950-30012  (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

1.833,0.448 2,0.198 2,0.198 2.583,0.198 true 1.802,1.667 2.302,1.667 true 2.344,1.604 2.76,1.854 0.417,0.25 10 false *1 2.625,0.135 3.125,0.385 0.5,0.25 10 false *2

*1	No. 1 Rear Differential Dust Deflector
*2	No. 2 Rear Differential Dust Deflector

Remove the 3 bolts, No. 1 rear differential dust deflector and No. 2 rear differential dust deflector from the electro magnetic control coupling sub-assembly.

Remove the 5 bolts and electro magnetic control coupling sub-assembly from the rear differential carrier assembly.

2.563,2.771 1.75,3 1.75,3 2.292,2.667 true 1.771,1.385 2.021,1.385 2.021,1.385 2.271,1.219 true 1.083,3.167 0.833,3.167 0.833,3.167 0.833,2.833 false 1.615,1.313 1.948,1.563 0.333,0.25 10 false *1 1.594,2.896 2.01,3.146 0.417,0.25 10 false *a 1.125,3.104 1.542,3.354 0.417,0.25 10 false SST

*1	Transmission Coupling Dust Seal
*a	Cloth

Secure the electro magnetic control coupling sub-assembly in a vise using aluminum plates and cloths.

NOTICE:

Do not overtighten the vise, as the electro magnetic control coupling sub-assembly may become deformed.

Secure the rear differential carrier assembly to the overhaul attachment.

Using a 10 mm socket hexagon wrench, remove the rear differential filler plug and gasket.

Using a 10 mm socket hexagon wrench, remove the rear differential drain plug and gasket.

Using an 8 mm socket hexagon wrench, remove the rear differential carrier cover plug.

Remove the bolt and transmission revolution sensor from the rear differential carrier assembly.

0.792,0.531 1.208,0.531 1.208,0.531 1.542,0.865 true 0.469,0.469 0.885,0.719 0.417,0.25 10 false SST

Using SST, remove the No. 2 4 wheel drive position switch from the rear differential carrier assembly.

SST

09816-30010  

Using a chisel and a hammer, lift the rear differential breather plug slightly.