Part 1

DIFFERENTIAL CARRIER ASSEMBLY REAR
OVERHAUL
1. REMOVE REAR WHEEL
2. REMOVE EXHAUST PIPE ASSEMBLY
3. REMOVE FRONT FLOOR HEAT INSULATOR NO.1
4. REMOVE PROPELLER SHAFT HEAT INSULATOR
5. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
6. REMOVE REAR DIFFERENTIAL FILLER PLUG
a. Using a hexagon wrench (10 mm), remove the filler plug and gasket.
7. REMOVE REAR DIFFERENTIAL DRAIN PLUG
a. Using a hexagon wrench (10 mm), remove the drain plug and gasket.
b. Drain the differential oil.
8. REMOVE REAR DRIVE SHAFT ASSEMBLY LH
9. REMOVE REAR DRIVE SHAFT ASSEMBLY RH

HINT: Removal procedure of the RH side is the same as that of the LH side.

10. REMOVE STABILIZER BAR REAR

HINT: Perform this procedure only when the rear differential mount cushion should be changed.

11. REMOVE HEIGHT CONTROL VALVE SUB-ASSEMBLY NO.2 (W/ AIR SUSPENSION)

HINT: Perform this procedure only when the rear differential mount cushion should be changed.

12. REMOVE DIFFERENTIAL CARRIER ASSEMBLY REAR





a. Support the differential carrier with a jack and wooden block.

NOTICE: Be careful not to drop the differential carrier assembly rear.

b. Using a hexagon wrench (12 mm), remove the 3 hexagon bolts.





c. Remove the 2 bolts and lower mount stoppers.
d. Remove the differential.
e. Remove the 2 upper mount stoppers from the differential carrier.





13. REMOVE REAR DIFFERENTIAL MOUNT CUSHION NO.1
a. Using SST, remove the rear differential mount cushion No.1.
SST 09570-24010, 09316-12010

HINT: Perform this operation only when the rear differential mount cushion No.1 is damaged.

NOTICE:
^ Do not bring the SST into contact with the sub-flame.
^ Do not slant the SST bolts.
^ Do not set the SST in the wrong direction.
^ Screw the 2 SST bolts equally into the 2 holes of the rear differential mount.





14. REMOVE REAR DIFFERENTIAL MOUNT CUSHION NO.2
a. Using SST remove the rear differential mount cushion No.2.
SST 09570-24010, 09316-12010

HINT: Perform this operation only when the rear differential mount cushion No.2 is damaged.

NOTICE:
^ Do not bring the SST into contact with the sub-flame.
^ Do not slant the SST bolts.
^ Do not set the SST in the wrong direction.

15. REMOVE REAR DIFFERENTIAL CARRIER COVER





a. Remove the 8 bolts from the carrier cover.





b. Using a brass bar and a hammer, separate the cover from carrier.
c. If necessary, remove the breather plug from the differential carrier cover.





d. Remove the bolt and oil deflector from the differential carrier cover.





16. FIX DIFFERENTIAL CARRIER ASSEMBLY REAR
a. Set the differential carrier to the overhaul stand, etc., as shown in the illustration.





17. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
a. Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 inch)
If the runout is greater than the maximum, replace the drive pinion, ring gear and differential case.





18. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using a dial indicator, measure the backlash of the ring gear at 3 points.
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)

NOTICE: The difference between the maximum and minimum measured values must be less than 0.05 mm (0.0020 inch).

If the backlash is not within the specification, adjust the back lash (see step 55).
19. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION





a. Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead primer.
b. Hold the companion flange firmly and rotate the ring gear in both directions.
c. Inspect the tooth contact pattern.








If tooth contact pattern is not correct, replace the adjusting washer installed on the front of the drive pinion rear bearing to adjust it.

NOTICE: Make sure to always replace the adjusting washer with a new one.

HINT: Refer to the table on the next page to select of the adjusting washer.





HINT: There are 42 thicknesses of the rear differential drive pinion plate washers available in 0.01 mm (0.004 inch) difference.





20. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
a. Using a vise, hold the differential case between two aluminum plates.
b. Place a dial indicator on the tip of the pinion gear tooth at a right angle. Hold the side gear in the differential case and check that the backlash is 0 mm (0 inch).
If the backlash is not within the specification, replace the rear differential case sub-assembly with a new one.





21. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION
a. Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 inch) away from the end of the shaft.
Maximum runout: 0.08 mm (0.0031 inch)
If the runout is greater than the maximum, replace the drive pinion and ring gear.





22. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Using SST and a torque wrench, measure the preload using the backlash of the drive pinion and ring gear.
SST 09229-55010
Drive pinion preload (at starting): 0.5 to 0.8 Nm (5 to 8 kgf-cm, 4.3 to 6.9 inch lbs.)
If the preload is not within the specification, adjust the rear differential drive pinion preload or repair as necessary.





23. INSPECT TOTAL PRELOAD
a. Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
SST 09229-55010
Total preload (at starting):
Drive pinion preload plus 0.46 to 1.37 Nm (4.69 to 13.97 kgf-cm, 4.07 to 12.13 inch lbs.)
If necessary, disassemble and inspect the differential.





24. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST, remove the 2 oil seals.
SST 09308-00010
25. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING





a. Install the SST to the rear differential carrier assembly.
SST 09571-50010





b. Install a dial indicator to the rear differential carrier assembly.
c. Tighten the SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.004 inch) clearance between the side bearing (outer race) and side gear shaft shaft snap ring.

NOTICE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 inch).

HINT:
^ Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side gear shaft oil seal is tapped in.
^ Approximately 0.1 mm (0.004 inch) clearance between the side bearing (outer race) and the side gear shaft shaft snap ring is sufficient enough for the washer to move slightly.





d. Using snap ring pliers, remove the side gear shaft shaft snap ring on the drive pinion side.

HINT: For reassembly purposes, measure the thickness of the side gear shaft shaft snap ring. Write down the result.

e. Remove the dial indicator and loosen the SST bolt.

NOTICE: Do not remove the SST.