Disassembly

Rear Differential

DISASSEMBLY
To detect the real cause of trouble, inspect the following items before disassembling.
^ Tooth contact of hypoid driven gear and drive pinion, and backlash
^ Hypoid driven gear runout on its back surface
^ Total preload of drive pinion

1. Set the ST on vise and install the differential assembly to ST.

ST 398217700 ATTACHMENT:

2. Drain the gear oil by removing the plug.
3. Remove the air breather cap.

NOTE:
^ Do not attempt to replace the air breather cap unless necessary.
^ Replace the air breather cap with a new one when removing.





4. Remove the bolts, and then remove the rear cover.





5. Keep the side bearing retainers RH and LH separately for easier reassembly. Remove the side bearing retainer attaching bolts, set the ST to differential case, and extract the side bearing retainers RH and LH with a puller.

NOTE: Each shim, which is installed to adjusted the side bearing preload, should be kept together with its mating retainer.

ST 398457700 ATTACHMENT:

6. Pull out the differential case assembly from differential carrier.

NOTE: Be careful not to hit the teeth against the case.





7. Remove the O-ring from side bearing retainer.
8. Remove the oil seal from the side bearing retainer.
9. Using the ST, remove the bearing cup from the side bearing retainer.

ST 398527700 PULLER ASSY:

10. Remove the bearing cone with ST.

NOTE:
^ Do not attempt to disassemble the parts unless necessary.
^ Set the puller so that its claws catch the edge of the bearing cone.
^ Never mix up the RH and LH bearing races and cones.

ST 18759AA000 PULLER ASSY:

11. Remove the hypoid driven gear by loosening the hypoid driven gear bolts.





12. Drive out the pinion shaft lock pin from hypoid driven gear side (Model without LSD).

NOTE: The lock pin is staked at the pin hole end on the differential carrier. Do not drive it out forcibly before removing the stake.

ST 899904100 STRAIGHT PIN REMOVER:

13. Draw out the pinion mate shaft and remove pinion mate gears, side gears and thrust washers. (Model without LSD)

NOTE: The gears should be marked or kept separated right and left, and front and rear as well as thrust washers.





14. Remove the self-locking nut while holding the companion flange with ST.

ST 498427200 FLANGE WRENCH:

15. Extract the companion flange with a puller.





16. Press the end of drive pinion shaft and extract it together with rear bearing cone, pinion height adjusting washer and washer.

NOTE: Hold the drive pinion so as not to drop it.

ST 398467700 DRIFT:

17. Remove the rear bearing cone from drive pinion by supporting the cone with ST.

NOTE: Place the replacer so that its center-recessed side faces the pinion gear.

ST 398517700 REPLACER:

18. Remove the front oil seal from differential carrier using ST.

ST 398527700 PULLER ASSY:

19. Remove the pilot bearing together with front bearing cone using ST.

ST 398467700 DRIFT:

20. When replacing the bearings, hit out the front bearing cup and rear bearing cup in this order from outside of the case using a brass bar.