Part 2
DIFFERENTIAL CARRIER ASSY REAR OVERHAUL Continued41. Ring gear side position: REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING
a. Using SST and a hammer, create a clearance between the side bearing (outer) 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 SST with a hammer three or four times should be enough.
b. Using snap ring pliers, remove the 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.
42. Ring gear side position: 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 SST
43. Except ring gear side position: 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.
44. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY
NOTICE: Be careful not to damage the case bearing.
45. REMOVE REAR DRIVE PINION NUT
a. Using a chisel and hammer, loosen the staked part of the nut.
b. Using SST to hold the drive pinion companion flange, remove the nut.
SST 09229-55010, 09950-30012 (09955-03040), 09330-00021 (09330-00030)
46. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR
a. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060)
47. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
48. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Using a magnet hand, remove the differential drive pinion oil slinger.
49. REMOVE DIFFERENTIAL DRIVE PINION
a. Using a press, press out the drive pinion with the rear bearing from the differential carrier.
NOTICE: Be careful not to drop the drive pinion.
50. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Remove the spacer from the drive pinion.
51. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Remove the front bearing from the differential carrier.
b. Using a brass bar and hammer, tap out the front bearing outer race.
52. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, press out the rear bearing from the drive pinion.
SST 09950-00020
NOTICE: Do not drop the drive pinion.
HINT: If the drive pinion or ring gear are damaged, replace them as a set.
b. Using a brass bar and hammer, tap out the rear bearing outer race.
c. Remove the plate washer.
53. 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-faced hammer, tap on the ring gear to separate it from the differential case.
54. INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSY
a. Install the differential case as shown in the illustration.
HINT: If the ring gear runout is within the specified value (see step 27), this inspection is not necessary.
NOTICE: Do not damage the case bearing.
b. Using SST and a hammer, tap in the outer race on the drive pinion side.
SST 09608-32010, 09950-70010 (09951-07200)
HINT: Tap in the outer race until half of the side gear shaft shaft snap ring groove of the differential carrier can be seen.
c. Place 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, tap in 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 runout.
Maximum runout: 0.05 mm (0.0020 inch)
If the runout is greater than the maximum, replace the rear differential case sub-assy with a new one.
55. Ring gear side position: 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 SST
56. Except ring gear side position: REMOVE REAR DIFFERENTIAL CASE BEARING
a. Raise the ring gear side of the differential case slightly to remove the drive pinion side outer race.
57. REMOVE REAR DIFFERENTIAL CASE SUB-ASSY
NOTICE: Be careful not to damage the side bearing.
58. 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)
HINT: Do not remove the case bearing when not replacing the differential case.
NOTICE:
^ Do not deform the bearing case.
^ Hook the claws of SST to the bearing inner race of the differential case.
59. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST and a press, press out the dust deflector.
SST 09950-60010 (09951-00440), 09950-00020, 09950-70010 (09951-07100)
NOTICE: Do not drop the differential carrier.
60. INSPECT DIFFERENTIAL PINION GEAR BACKLASH
a. Using a vise, hold the differential case between 2 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 as specified, replace the rear differential case sub-assy with a new one.
61. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
HINT: Perform this procedure only when replacing the dust cover.
a. Using SST and a press, press a new dust deflector into the companion flange.
SST 09316-60011 (09316-00011)
NOTICE:
^ Slowly press a new dust deflector into the companion flange while observing the dust deflector. Do not press excessively.
^ If necessary, remove any burrs after inserting the new dust deflector.
62. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case and ring gear.
b. Heat the ring gear in boiling water that is approximately 100°C (212°F).
c. Carefully take the ring gear out of 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 cooled sufficiently.
63. INSTALL REAR DIFFERENTIAL CASE BOLT
a. Clean the differential ring gear set bolt hole.
b. Wait until the ring gear has cooled sufficiently.
c. Apply thread lock to 8 new ring gear set bolts.
Thread lock: Part No. 08833-00100, THREE BOND 1360 K or equivalent.
NOTICE: Always use new ring gear set bolts.
d. Install the 8 ring gear set bolts to the ring gear.
e. Torque the 10 set bolts uniformly and a little at a time.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
f. Tighten the bolts further by 60 to 90°.
NOTICE: Tighten the bolts in diametrically opposite pairs.
64. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, press in the 2 differential case bearings.
SST 09950-60010 (09951-00560), 09950-60020 (09951-00810), 09950-70010 (09951-07100, 09951-07200)
NOTICE:
^ Align SST with the center of the differential case.
^ Replace the bearing outer race when bearing is replaced.
^ Be careful as the 2 bearings are different. The ring gear tooth side's bearing is part no. 90366-50087 and the other side's bearing is part no. 90366-50027.
65. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, press in the rear bearing.
SST 09502-24010
b. Using SST and a press, press in the rear bearing outer race and adjusting washer.
SST 09255-10012, 09950-70010 (09951-07100)
HINT: Select a thrust shim of the same thickness as the removed one.
66. INSTALL DIFFERENTIAL DRIVE PINION
a. Using SST and a press, press in the front bearing outer race.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07200)
b. Install the drive pinion in the differential carrier.
c. Using SST and a press, press in the front bearing on the drive pinion.
HINT: Assemble the spacer and oil seal after adjusting the tooth contact pattern.
SST 09316-60011 (09316-00011), 09608-04031
67. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Using SST, install the companion flange onto the differential carrier.
SST 09950-30012(09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060)
NOTICE: Because the spacer is not installed, maintain a little looseness between the companion flange and the drive pinion when installing.
b. Adjust the drive pinion preload by tightening the companion flange nut.
HINT: Tighten the nut using approximately 98 Nm (1,000 kgf-cm, 72 ft. lbs.) of force. Then tighten it further while observing the preload.
1. Using SST to hold the flange, tighten the nut.
SST 09229-55010, 09550-30012 (09955-03040), 09330-00021 (09330-00030)
c. Using SST and a torque wrench, measure the preload.
SST 09229-55010
Preload (at starting):
HINT:
^ Do not apply hypoid gear oil if a new bearing is used.
^ If the preload is not within the specification, adjust the rear differential drive pinion preload or repair as necessary.
NOTICE: For a more accurate measurement, rotate the bearing forward and backward several times before measuring.
68. INSTALL REAR DIFFERENTIAL CASE SUB-ASSY
a. Insert the differential case from the ring gear tooth side to install.
NOTICE: Do not damage the case bearing and ring gear.
69. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST and a hammer, tap in the drive pinion side outer race.
SST 09608-32010, 09950-70010 (09951-07200)
HINT: Tap in the outer race until half of the side gear shaft shaft snap ring groove of the differential carrier can be seen.
b. Install SST to the differential carrier.
SST 09571-50010
c. Tighten the SST bolt until the SST disc lightly touches to the case bearing (outer race).
d. Using SST and a hammer, tap in the ring gear side outer race.
SST 09950-70010 (09951-07200), 09608-32010
HINT: Tap in the outer race until it touches the case bearing roller.