AXLE AND DIFFERENTIAL  REAR DIFFERENTIAL CARRIER ASSEMBLY  DISASSEMBLY  

Using 2 nuts, remove the 4 stud bolts from the transmission coupling assembly.

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.

Using a chisel and hammer, slightly pry out the rear differential carrier cover breather plug.

*a	Vertical Runout
*b	Lateral Runout

Attach a lever probe to a dial indicator and set the probe at a right angle to the inner surface of the transmission coupling assembly.

Remove the 4 bolts, and, using a brass bar and hammer, lightly tap the transmission coupling assembly to remove it from the rear differential carrier assembly.

NOTICE:

·

Put the brass bar against the rib of the transmission coupling assembly.

·

When removing the transmission coupling assembly, be careful not to scratch the installation surface.

HINT:

To prevent the transmission coupling assembly from falling, leave 2 of the bolts screwed in by 5 or 6 threads.

Using a snap ring expander, remove the snap ring.

Remove the 4WD linear solenoid from the yoke.

Remove the O-ring from the 4WD linear solenoid.

Using a 5 mm socket hexagon wrench, remove the 2 bolts and the yoke from the rear differential carrier sub-assembly.

*1	Transmission Coupling Conical Spring Washer

Remove the transmission coupling conical spring washer from the rear differential carrier sub-assembly.

*1	Transmission Coupling Shim

Remove the transmission coupling shim from the rear differential carrier sub-assembly.

*a	Turn
*b	Hold

Insert a dial indicator into the rear differential side gear shaft oil seal hole, and place it perpendicular to the edge of a ring gear tooth.

Using SST and a torque wrench, measure the preload (starting torque) of the backlash between the differential drive pinion and differential ring gear.

SST

09556-52010  

Standard:

0.77 to 1.26 N*m (8 to 12 kgf*cm, 7 to 11 in.*lbf)

Using SST and a torque wrench, measure the preload (at the start of torque) with the teeth of the drive pinion and differential ring gear in contact.

SST

09556-52010  

Standard:

Total preload = drive pinion preload + 0.58 to 1.01 N*m (6 to 10 kgf*cm, 5 to 8 in.*lbf)

NOTICE:

Measure the preload after rotating the case bearing several times in the forward and reverse directions to make sure the bearing is operating correctly.

*1	Rear Drive Shaft Oil Seal RH

Using SST, remove the rear drive shaft oil seal RH from the rear differential carrier sub-assembly.

SST

09308-00010  

*1	Diaphragm Oil Seal
*a	Turn
*b	Hold

Using SST, remove the diaphragm oil seal from the rear differential carrier sub-assembly.

SST

09308-10010  

Using SST and a hammer, loosen the staked part of the rear drive pinion nut.

SST

09930-00010  

NOTICE:

·

Use SST with the tapered surface facing the shaft side.

·

Do not grind the end of SST with a grinder or other tool.

·

Completely loosen the staked part of the rear drive pinion nut.

·

Do not damage the threads of the differential drive pinion.

*a	Turn
*b	Hold

Using SST, secure the differential drive pinion and remove the rear drive pinion nut from the differential drive pinion.

SST

09556-52010  09564-16020  

*a	Turn
*b	Hold

Using SST, remove the rear drive pinion front tapered roller bearing (inner race) from the rear differential carrier sub-assembly.

SST

09556-30010  

Remove the 8 bolts.

Using a brass bar and hammer, lightly tap the differential side bearing retainer and remove it.

NOTICE:

·

Put the brass bar against the rib of the differential side bearing retainer.

·

When removing the differential side bearing retainer, be careful not to scratch the installation surface.

HINT:

Prevent the differential side bearing retainer from falling by screwing in 2 bolts by 5 or 6 threads.

Remove the rear differential case sub-assembly from the rear differential carrier sub-assembly.

Remove the differential drive pinion from the rear differential carrier sub-assembly.

NOTICE:

If either the rear differential drive pinion or the differential ring gear has been scratched, replace both.

Remove the rear differential drive pinion bearing spacer from the differential drive pinion.

Using SST and a press, remove the rear drive pinion rear tapered roller bearing (inner race) from the differential drive pinion.

SST

09950-00020  

NOTICE:

If the rear differential driver pinion or differential ring gear is damaged, replace them both.

*a	Turn
*b	Hold

Attach the claws of SST to the rear drive pinion front tapered roller bearing (outer race) from the notches in the differential carrier sub-assembly.

SST

09612-65014  (09612-01020, 09612-01050)

Using a brass bar and hammer, uniformly lightly tap the rear drive pinion rear tapered roller bearing (outer race) and remove it.

NOTICE:

Put the brass bar into one of the notches.

*1	Rear Differential Side Gear Shaft Washer
*2	Rear Differential Case Bearing RH (Outer Race)

Using SST and a press, remove the rear differential case bearing RH (outer race) and rear differential side gear shaft washer from the rear differential carrier sub-assembly.

SST

09950-60011  (09951-00510)
09950-70010  (09951-07100)

*1	Rear Differential Side Gear Shaft Washer
*2	Rear Differential Case Bearing LH (Outer Race)

Using SST and a press, remove the rear differential case bearing LH (outer race) and rear differential side gear shaft washer from the differential side bearing retainer.

SST

09950-60011  (09951-00460)
09950-70010  (09951-07100)
09649-17010  

*a	Turn
*b	Hold

Using SST, remove the rear differential case bearing RH (inner race) from the rear differential case sub-assembly.

SST

09950-40011  (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011)
09950-60011  (09951-00320)

NOTICE:

Before using SST center bolt (09953-04020), apply oil to its threads and tip.

HINT:

·

If the race remains on the rear differential case sub-assembly, repeat the step above to remove the rear differential case bearing RH (inner race).

·

If the rear differential case bearing RH (inner race) is deformed, replace it with a new one.

*a	Turn
*b	Hold

Using SST, remove the rear differential case bearing LH (inner race) from the rear differential case sub-assembly.

SST

09950-40011  (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011)
09950-60011  (09951-00320)

NOTICE:

Before using SST center bolt (09953-04020), apply oil to its threads and tip.

HINT:

·

If the race remains on the rear differential case sub-assembly, repeat the step above to remove the rear differential case bearing LH (inner race).

·

If the rear differential case bearing LH (inner race) is deformed, replace it with a new one.

*a

Matchmark

Mount the rear differential case sub-assembly in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

Using a 5 mm socket hexagon wrench, remove the 2 bolts and rear differential breather plug oil deflector.

Remove the 4 straight pins from the rear differential carrier sub-assembly.