Part 2

DIFFERENTIAL CARRIER ASSEMBLY REAR
OVERHAUL





26. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING
a. Using SST and a hammer, create a clearance between the side bearing (outer race) on the ring gear and side gear shaft shaft snap ring.
SST 09608-32010, 09950-70010 (09951-07200)

HINT: The clearance cannot be seen, but tapping the SST with a hammer three or four times should be enough.





b. Using snap ring pliers, remove the side gear shaft shaft snap ring on the ring gear side.

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





27. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Tighten the SST bolt and push out the outer race on the ring gear side.
SST 09571-50010

NOTICE: Do not drop the side bearing (outer race).

b. Remove the SST





28. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Raise the ring gear of the differential case slightly to remove the drive pinion side outer race.

HINT: For reassembly, check the installation position of the outer race and the side gear shaft shaft snap ring before removing the outer race. Write down the result.





29. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

NOTICE: Do not damage the case bearing.

30. 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 flange, remove the nut.
SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)





31. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
a. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03060)

NOTICE: Apply hypoid gear oil to the SST center bolt tip and threads before use.





32. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, remove the dust deflector.
SST 09950-60010 (09951-00440), 09950-00020, 09950-70010 (09951-07100)





33. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
34. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Using a magnet hand, remove the differential drive pinion oil slinger.





35. REMOVE DIFFERENTIAL DRIVE PINION
a. Using a press, remove the drive pinion with the rear bearing from the differential carrier.

NOTICE: Be careful not to drop the drive pinion.





36. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Remove the spacer from the drive pinion.
37. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING





a. Remove the front bearing from the differential carrier.





b. Using a brass bar and a hammer, remove the front bearing outer race.
38. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING





a. Using SST and a press, remove the rear bearing from the drive pinion.
SST 09950-00020





b. Using a brass bar and a hammer, remove the rear bearing outer race.
c. Remove the plate washer.
39. REMOVE DIFFERENTIAL RING GEAR





a. Place matchmarks on the ring gear and differential case.





b. Remove the 10 ring gear set bolts.





c. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
40. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY





a. Install the drive side bearing in the differential carrier first, as shown in the illustration, then install the differential case.

NOTICE: Do not damage the case bearing.





b. Using SST and a hammer, install the outer race on the drive pinion side.
SST 09608-32010, 09950-70010 (09951-07200)

HINT: Tap in the outer race until half on the side gear shaft shaft snap ring groove of the differential carrier can be seen.





c. Place the SST on the differential carrier.
SST 09571-50010
d. Tighten the SST bolt until the SST disc lightly touches the case bearing (outer race).





e. Using SST and a hammer, install the outer race on the ring gear side.
SST 09950-70010 (09951-07200), 09608-32010

HINT: Tap in the outer race until it touches the case bearing roller.

f. Place a dial indicator on the differential case flange surface at a right angle.





g. Using a dial indicator, measure the differential case run out.
Maximum runout: 0.05 mm (0.0020 inch)
If the runout is greater than the maximum, replace the rear differential case sub-assembly with a new one.
41. REMOVE REAR DIFFERENTIAL CASE BEARING





a. Tighten the SST bolt to push out the ring gear side outer race.
SST 09571-50010

NOTICE: Do not drop the side bearing (outer race).

b. Remove the SST





42. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Raise the ring gear side of the differential case slightly to remove the drive pinion side outer race.





43. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY

NOTICE: Do not damage the side bearing.





44. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the 2 differential case bearings from the differential case.
SST 09950-60010 (09951-00480), 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)

NOTICE:
^ Apply hypoid gear oil to the SST center bolt tip and threads before use.
^ Do not deform the bearing case.
^ Hook the claws of the SST to the bearing inner race from the differential case.





45. INSPECT DIFFERENTIAL PINION 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.
46. INSTALL DIFFERENTIAL RING GEAR





a. Clean the contact surfaces of the differential case and the threads of the ring gear and differential case.
b. Heat the ring gear to approximately 100°C (212°F) in boiling water.
c. Carefully remove the ring gear from the boiling water.





d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

HINT: Align the matchmarks on the ring gear and the differential case.

e. Tighten the new 2 bolts temporarily so that the bolt holes in the ring gear and differential case are not misaligned.

NOTICE: The ring gear set bolts should not be tightened until the ring gear has been cooled sufficiently.

47. INSTALL REAR DIFFERENTIAL CASE BOLT





a. Clean the differential ring gear set bolt hole.
b. After the ring gear has been cooled sufficiently, install the new 8 ring gear set bolts to which thread lock has been applied.
Thread lock: Part No. 08833-00100, THREE BOND 1360 K or equivalent.

NOTICE: New ring gear set bolts should be used in every case.





c. Torque the 10 set bolts uniformly and a little at a time.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
d. Tighten the bolts further by 60 to 90°.

NOTICE: Tighten the bolts in diagonally opposite pairs.





48. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, install the 2 differential case bearings.

SST 09950-60010 (09951-00560), 09950-70010 (09951-07100), 09950-60020 (09951-00810), 09950-70010 (09951-07100)

NOTICE:
^ Align the SST with the center of the differential case.
^ Replace the bearing outer race when bearing is re placed.
^ The ring gear tooth (90366-50087) and back surfaces (90366-50027) have different bearing. Because of this, install the ring gear paying attention to their part numbers.

49. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING





a. Using SST and a press, install the rear bearing.
SST 09502-24010





b. Using SST and a press, install the rear bearing outer race and adjusting washer.
SST 09950-70010 (09951-07100), 09255-10012

HINT: Select a thrust shim of the same thickness as the removed one.