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# REAR DIFFERENTIAL CARRIER ASSEMBLY > DISASSEMBLY

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1. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY

2. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR

1. Using a dial indicator, measure the runout of the companion flange vertically and laterally.

   Maximum runout:

     Runout | Maximum
     Vertical runout | 0.10 mm (0.0039 in.)
     Lateral runout | 0.10 mm (0.0039 in.)

   1. If the runout is greater than the maximum, replace the companion flange.

3. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

1. Using a dial indicator, check the runout of the ring gear.

   Maximum runout:
     0.07 mm (0.0028 in.)
   1. If the runout is greater than the maximum, replace the ring gear with a new one.

4. INSPECT DIFFERENTIAL RING GEAR BACKLASH

1. Using a dial indicator, check the backlash of the ring gear.

   Backlash:
     0.13 to 0.18 mm (0.0051 to 0.0071 in.)
   1. If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

      HINT:
        Perform the measurements at 3 or more positions around the side bearing preload.

5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

1. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.

   Total preload (at start of torque):
     0.56 to 0.85 N*m (6 to 9 kgf*cm, 4.9 to 7.5 in.*lbf)
   1. If necessary, disassemble and inspect the differential.

6. INSPECT TOTAL PRELOAD

1. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

1. Using a torque wrench, measure the total preload.

   Torque:
     Total preload (at start of torque):
     0.39 to 0.59 N*m{ 4 to 6 kgf*cm , 3.4 to 5.2 in.*lbf } + drive pinion preload
   1. If necessary, disassemble and inspect the differential.

7. REMOVE REAR DRIVE PINION NUT

1. Using SST and a hammer, loosen the staked part of the nut.

   SST
     09930-00010 (09931-00010, 09931-00020)

1. Using SST to hold the companion flange in place, remove the nut.

   SST
     09330-00021 (09330-00030)

8. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

1. Using SST, remove the companion flange.

   SST
     09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)

   NOTICE:
     Before using SST (center bolt), apply hypoid gear oil to is threads and tip.

9. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

1. Using SST and a press, press out the dust deflector.

   SST
     09950-60010 (09951-00380)
     09950-70010 (09951-07150)
     09950-00020

   NOTICE:
     Do not drop the companion flange.

10. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

1. Using SST, remove the oil seal from the differential carrier.

   SST
     09308-10010

11. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

12. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

1. Using SST, remove the roller bearing (inner) from the drive pinion.

   SST
     09556-22010

13. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK

1. Remove the 2 bolts and 2 adjusting locks.

14. REMOVE DIFFERENTIAL CASE ASSEMBLY

1. Place matchmarks on the bearing cap and differential carrier.

1. Remove the 4 bolts and 2 differential bearing caps.

1. Remove the 2 adjusting nuts.

1. Remove the rear differential case bearings from the differential carrier.

   HINT:
     Tag the 2 case bearing outer races to show the location for reassembling.

15. REMOVE DIFFERENTIAL DRIVE PINION

1. Remove the drive pinion and bearing spacer from the differential carrier.

16. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

1. Using SST and a press, press out the roller bearing (inner) from the drive pinion.

   SST
     09950-00020

   NOTICE:
     Do not drop the drive pinion.

   HINT:
     If the drive pinion or ring gear is damaged, replace them as a set.

17. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

1. Using SST, remove the roller bearing (outer) from the carrier.

   SST
     09308-00010

1. Using a brass bar and hammer, tap out the oil storage ring from the carrier.

   HINT:
     If the bearing is damaged during removal, replace it.

19. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

1. Using a brass bar and hammer, tap out the rear tapered roller bearing (outer) from the carrier.

   HINT:
     If the bearing is damaged during removal, replace it.

20. REMOVE DIFFERENTIAL RING GEAR

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

1. Using a screwdriver and hammer, pry out the lock plates.

1. Remove the 10 ring gear set bolts and 5 lock plates.

1. Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.

21. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT

HINT:

  If the ring gear runout is within the specified value.

1. Install the rear differential case bearing to the differential case.

1. Install the differential case to the differential carrier.

1. Install the 2 bearing caps to the differential carrier with the 4 bolts.

   Torque:
     85 N*m{ 867 kgf*cm , 63 ft.*lbf }

1. Inspect the differential case runout.

   Maximum runout:
     0.07 mm (0.0028 in.)

1. Remove the differential case.

1. Remove the rear differential case bearing.

22. REMOVE REAR DIFFERENTIAL CASE BEARING

1. Using SST, remove the 2 bearings from the differential case.

   SST
     09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)
     09950-60010 (09951-00360)

   HINT:
     Do not remove the case bearing when not replacing the differential case.

23. DISASSEMBLE DIFFERENTIAL CASE (for 2 Pinion Gear Type)

1. Using a pin punch and hammer, tap out the straight pin.

1. Remove the following parts from the differential case.

   1. (1) Side gear (2 pieces)
   2. (2) Side gear thrust washer (2 pieces)
   3. (3) Pinion shaft
   4. (4) Pinion gear (2 pieces)
   5. (5) Pinion gear thrust washer (2 pieces)

1. Using a chisel and hammer, unstake the differential case.

24. DISASSEMBLE DIFFERENTIAL CASE (for LSD)

1. Place matchmarks on the LH and RH cases.

1. Remove the 8 bolts.

   NOTICE:
     Diametrically loosen and remove the bolts in several passes.

1. Remove the following parts from the differential cases.

   1. (1) Side gear (2 pieces)
   2. (2) No. 1 side gear thrust washer (6 pieces)
   3. (3) Clutch plate (6 pieces)
   4. (4) Side gear thrust washer (2 pieces)

   5. (5) Spring retainer RH
   6. (6) Spring retainer LH
   7. (7) Compression spring
   8. (8) Pinion gear (4 pieces)
   9. (9) Pinion gear thrust washer (4 pieces)
   10. (10) Spider

25. INSPECT REAR NO. 1 DIFFERENTIAL SIDE GEAR THRUST WASHER (for LSD)

1. Using a micrometer, measure the thickness of the thrust washer. Also, check that there is no bare metal.

   Standard thickness:
     1.77 to 186 mm (0.0697 to 0.0732 in.)
   1. If necessary, replace the thrust washers.

      HINT:
        If replacing the thrust washer, also replace the clutch plate that it contacts.

26. INSPECT CLUTCH PLATE (for LSD)

1. Using a micrometer, measure the thickness of the clutch plate. Also, check that there is no abnormal wear.

   Standard thickness:
     1.57 to 1.63 mm (0.0618to 0.0642 in.)
   1. If necessary, replace the clutch plate.

27. INSPECT COMPRESSION SPRING (for LSD)

1. Using a vernier caliper, measure the free length of the spring.

   Minimum free length:
     27.11 mm (1.067 in.)
   1. If the length is less than the minimum, replace the spring.

28. INSPECT DIFFERENTIAL PINION AND SIDE GEAR

1. Check that the differential pinion and differential side gear are not damaged.

   1. If the differential pinion or differential side gear is not damaged, replace the differential.

29. INSPECT DIFFERENTIAL CASE

1. Check that the differential case is not damaged.

   1. If the differential case is damaged, replace it.