Part 1
Part 1DIFFERENTIAL CARRIER ASSEMBLY REAR (4WD)
OVERHAUL
COMPONENTS
1. REMOVE REAR WHEEL
2. REMOVE REAR DIFFERENTIAL CARRIER COVER PLUG
a. Using a hexagon wrench (10 mm), remove the rear differential carrier cover plug (filler plug) and gasket.
3. REMOVE REAR DIFFERENTIAL DRAIN PLUG
a. Using a hexagon wrench (10 mm), remove the rear differential drain plug and gasket, drain the oil.
b. Install the rear differential drain plug and a new gasket.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
4. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
SST 09325-20010
5. REMOVE EXHAUST PIPE ASSEMBLY
6. SEPARATE REAR STABILIZER LINK ASSEMBLY LH
7. SEPARATE REAR STABILIZER LINK ASSEMBLY RH
HINT: Separate the RH side by the same procedures as LH side.
8. REMOVE REAR AXLE SHAFT LH NUT
9. REMOVE REAR AXLE SHAFT RH NUT
HINT: Remove the RH side by the same procedures as LH side.
10. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY
11. SEPARATE SPEED SENSOR REAR LH
12. SEPARATE SPEED SENSOR REAR RH
HINT: Remove the RH side by the same procedures as LH side.
13. REMOVE FRONT BRAKE SHOE
SST 09718-00010
14. REMOVE PARKING BRAKE SHOE STRUT SET LH SST 09703-30010
15. REMOVE PARKING BRAKE SHOE STRUT SET RH
SST 09703-30010
HINT: Remove the RH side by the same procedures as LH side.
16. REMOVE REAR BRAKE SHOE
SST 09718-00010
17. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO.3
18. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO.2
HINT: Remove the No.2 by the same procedures as No.3.
19. SEPARATE REAR BRAKE TUBE NO.4
20. SEPARATE REAR BRAKE TUBE NO.3
HINT: Remove the tube No.3 by the same procedures as tube No.4.
21. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.1 LH
22. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.1 RH
HINT: Separate the RH side by the same procedures as LH side.
23. SEPARATE UPPER CONTROL ARM ASSEMBLY
24. REMOVE REAR AXLE ASSEMBLY LH
25. REMOVE REAR AXLE ASSEMBLY RH
HINT: Remove the RH side by the same procedures as LH side.
26. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY
27. REMOVE REAR DRIVE SHAFT ASSEMBLY LH
28. REMOVE REAR DRIVE SHAFT ASSEMBLY RH
HINT: Remove the RH side by the same procedures as LH side.
29. REMOVE DIFFERENTIAL CARRIER ASSEMBLY REAR
a. Remove the 2 rear mounting bolts.
b. Remove the 2 bolts, 2 nuts and rear differential with support front side.
30. REMOVE DIFFERENTIAL SUPPORT
a. Remove the 3 bolts and differential support from the differential.
31. REMOVE REAR DIFFERENTIAL SUPPORT NO.1
a. Remove the 2 bolts, 2 nuts and differential support No.1 from the differential.
32. FIX DIFFERENTIAL CARRIER ASSEMBLY REAR
33. REMOVE REAR DIFFERENTIAL FILLER PLUG
a. Using a hexagon wrench (17 mm), remove the rear differential filler plug (inspection plug) and gasket.
34. INSPECT RUNOUT OF TRANSMISSION COUPLING ASSEMBLY
a. Using SST and a dial indicator, measure the runout of the transmission coupling vertically.
SST 09564-32011
Maximum runout: 0.05 mm (0.002 inch)
b. Using SST and a dial indicator, measure the runout of the transmission coupling horizontally.
SST 09564-32011
Minimum runout: 0.05 mm (0.002 inch)
35. REMOVE REAR DIFFERENTIAL CARRIER COVER
a. Remove the 4 bolts and differential carrier cover.
36. REMOVE TRANSMISSION COUPLING CONICAL SPRING WASHER
37. REMOVE TRANSMISSION COUPLING SPACER
38. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
a. Using a screwdriver, remove the rear differential dust deflector.
HINT: Tape the screwdriver tip before use.
39. REMOVE TRANSMISSION COUPLING ASSEMBLY
a. Remove the transmission coupling assembly from the differential carrier cover.
40. REMOVE TRANSMISSION COUPLING RADIAL BALL BEARING
a. Using SST and a press, remove the transmission coupling radial ball bearing (No.1).
SST 09950-00020, 09950-60020 (09951-00910), 09950-70010 (09951-07150)
41. REMOVE TRANSMISSION COUPLING RADIAL BALL BEARING
a. Using SST and a press, remove the transmission coupling radial ball bearing (No.2).
SST 09950-00020, 09950-60010 (09951-00460, 09951-00530, 09952-06010), 09950-70010 (09951-07150)
42. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Using SST and a dial indicator, measure the backlash of ring gear while holding the drive pinion.
SST 09556-16011, 09564-32011
Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 inch)
NOTICE: Measure at least 3 positions on the circumference of the ring gear.
43. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload of the back lash between the drive pinion and ring gear.
SST 09556-16011
Preload (at starting): 0.4 to 0.7 Nm (4 to 7 kgf-cm, 3.0 to 6.0 inch lbs.)
HINT: To make the case bearing smooth, turn clockwise and counter clockwise several times before measuring.
If necessary, disassemble and inspect the differential.
44. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST, remove the 2 side gear shaft oil seals from the housing.
SST 09308-00010
45. REMOVE REAR DRIVE PINION NUT
a. Using SST and a hammer, unstake the rear drive pinion nut.
SST 09930-00010
NOTICE: Loosen the staked part of the lock nut completely, other wise the screw of the drive pinion may be damaged.
b. Using SST to hold the drive pinion, remove the rear drive pinion nut.
SST 09564-16020, 09556-16011
46. REMOVE OIL DIAPHRAGM SEAL
a. Using SST, remove the oil diaphragm seal. SST 09308-10010
47. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST, remove the rear drive pinion front tapered roller bearing (inner race) from the drive pinion.
SST 09556-30010
48. REMOVE DIFFERENTIAL PRESSURE CONTROL HOSE
a. Remove the 2 differential pressure control hose clips and differential pressure control hose.
49. REMOVE DIFFERENTIAL PRESSURE CONTROL HOSE ELBOW
a. Put matchmarks on the differential pressure control hose elbows and differential carrier.
b. Using a screwdriver, remove the 2 differential pressure control hose elbows.
HINT: Tape the screwdriver tip before use.
50. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
a. Remove the 10 bolts from the differential carrier.
b. Using a brass bar and a hammer, remove the side bearing retainer from the differential carrier.
NOTICE: Place the brass bar on the rib of differential side bearing retainer.
51. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY
52. REMOVE REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG
a. Using a screwdriver, remove the rear differential carrier cover breather plug from the side bearing retainer.
HINT: Tape the screwdriver tip before use.
53. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
a. Remove the 2 bolts and rear differential breather plug oil deflector.
54. REMOVE DIFFERENTIAL DRIVE PINION
55. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
56. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
57. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST and a press, remove the rear drive pinion rear tapered roller bearing (inner race) from the drive pinion.
SST 09950-00020
HINT: If the drive pinion and ring gear are damaged, replace them as a set.
b. Remove the plate washer.
58. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST, remove the rear drive pinion front tapered roller bearing (outer race) from the differential carrier.
SST 09612-65014 (09612-01020, 09612-01050)
59. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, remove the rear drive pinion rear tapered roller bearing (outer race) from the differential carrier.
60. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, remove the rear differential side gear shaft washer plate and rear differential case bearing RH (outer race).
SST 09950-60010 (09951-00580), 09950-70010 (09951-07100)
61. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST and a press, remove the rear differential side gear shaft washer plate and rear differential case bearing LH (outer race).
SST 09950-60010 (09951-00580), 09950-70010 (09951-07100), 09223-15020
62. REMOVE STRAIGHT PIN
a. Remove the 4 straight pins from the differential carrier.
63. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the case bearing RH (inner race) from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011), 09950-60010 (09951-00270, 09951-00370, 09952-06010)
64. REMOVE REAR DIFFERENTIAL CASE BEARING
a. Using SST, remove the case bearing LH (inner race) from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00270, 09951-00370, 09952-06010)
65. REMOVE DIFFERENTIAL RING GEAR
a. Put matchmarks on the ring gear and differential case.
b. Remove the 10 ring gear set bolts.
c. Using a plastic hammer, tap the ring gear to separate it from the differential case.
66. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY
a. Using a pin punch and a hammer, remove the rear differential pinion shaft pin.
b. Remove the rear differential pinion shaft, 2 differential pinion gears, 2 rear differential pinion thrust washers, 2 differential side gears and 2 rear differential side gear thrust No.1 washers.
67. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
a. Check the differential pinion gear and differential side gear for wear.
68. INSPECT REAR DIFFERENTIAL CASE SUB-ASSEMBLY
a. Check the differential case for a crack or a damage.
69. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
a. Install the 2 proper rear differential side gear thrust No.1 washers on the 2 differential side gears.
NOTICE:
^ When installing a thrust washer, side gear, pinion check for dust or chip.
^ When replacing a side gear and a pinion, replace both of them together.
^ Apply hypoid gear oil to the sliding part and rotating part.
b. Install the 2 differential side gears, 2 differential pinion gears, 2 rear differential pinion thrust washers and rear differential pinion shaft in the differential case.
HINT: Align the holes of the differential case and rear differential pinion shaft.
c. Measure the differential side gear backlash with holding 1 differential pinion gear toward the differential case.
Backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 inch)
If the backlash is not within the specification, install the 2 rear differential side gear thrust No.1 washers with different thicknesses.
HINT: Refer to the table and select 2 rear differential side gear thrust No.1 washers which ensures that the backlash is within the specification.
Side gear thrust No.1 washer
d. Using a pin punch and a hammer, install the rear differential pinion shaft pin through the differential case and hole of the pinion shaft.
e. Using a chisel and a hammer, stake the outside of the differential case pin hole.