Disassembly

REMOVAL OF DIFFERENTIAL CASE ASSEMBLY





1. Using two 45 mm (1.77 inch) spacers, mount carrier on Tool.
Tool number: KV38100800 (J25604-01)





2. For proper reinstallation, paint match marks on one side of the bearing cap.
Bearing caps are line-board during manufacture. Replace them in their proper positions.





3. Remove bearing caps.





4. Lift differential case assembly out with Tool.
Tool number: HT72400000 (-)





Keep the side bearing outer races together with inner race. Do not mix them up. Also, keep adjusting washers together with bearings.

REMOVAL OF DRIVE PINION ASSEMBLY





1. Put matchmarks on companion flange and drive pinion with paint.





2. Loosen drive pinion nut and pull off companion flange.
Tool number: KV40104000 (-)





3. Take out drive pinion (together with rear bearing inner race, pinion bearing adjusting spacer).
4. Remove front oil seal. Refer to "FRONT OIL SEAL".
5. Remove pinion front bearing inner race.
6. Remove side oil seal. Refer to "SIDE OIL SEAL".





7. Remove pinion bearing outer races with a brass drift.





8. Remove pinion rear bearing inner race and drive pinion height adjusting washer with Tool.
Tool number: ST30031000 (J22912-01)

DISASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY





1. Remove side bearing inner race.
To prevent damage to bearing, engage puller jaws in groove.
Tool number:
A: ST3305S001
B: ST33061000 (J8107-2)





^ Be careful not to confuse left- and right-hand parts.





2. Loosen ring gear bolts in a criss-cross fashion.
3. Tap ring gear off the differential case with a soft hammer.
^ Tap evenly all around to keep ring gear from binding.





4. Drive out pinion mate shaft lock pin with punch from ring gear side.

INSPECTION
Contact Surfaces
1. Clean the disassembled parts in suitable solvent and blow dry with compressed air.
2. If following surfaces are found to be burred or scratched, smooth with oil stone.
^ Differential case
^ Side gear
^ Pinion mate gear
^ Pinion mate shaft

Bearing





1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged, replace outer race and inner race as a set.