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Removal of Differential
(See page RA±27)
1. DRAIN DIFFERENTIAL OIL
2. REMOVE DRIVE SHAFTS
(See page RA±20)
3. REMOVE REAR CROSSMEMBER
4. DISCONNECT PROPELLER SHAFT
(a) Place the matchmarks on the both flanges.
(b) Remove the four bolts, washers and nuts.
(c) Disconnect the propeller shaft from the differential.
S. REMOVE DIFFERENTIAL
(a) Jack up the differential slightly.
(b) Remove the two bolts.
(d) Remove the differential from the body. (c) Remove the four nuts and bolts.
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±31
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Differential Carrier
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±32
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2. CHECK COMPANION FLANGE RUNOUT
Using a dial indicator, measure the lateral and radial
runout of the companion flange.
Maximum lateral runout: 0.10 mm (0.0039 in.)
Maximum radial runout: 0.10 mm (0.0039 in.)
If the runout is greater than the maximum, replace the
companion flange.
4. CHECK RING GEAR BACKLASH
Using a dial indicator, check the backlash of the ring
gear.
Backlash: 0.13 mm ± 0.18 mm (0.0051 ± 0.0071 in.)
If the backlash is not within specification, adjust the
side bearing preload. 3. CHECK RING GEAR RUNOUT
Using a dial indicator, measure the runout of the ring
gear.
Maximum runout: 0.07 mm (0.0028 in.)
If the runout is greater than the maximum, replace the
ring gear.
PRE±INSPECTION OF DIFFERENTIAL
CARRIER
1. REMOVE DIFFERENTIAL CARRIER COVER
(a) Remove the eight bolts.
(b) Using a brass bar and hammer, separate the cover and
carrier. .
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±33
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6. CHECK SIDE GEAR BACKLASH
Using a dial indicator, check the backlash of the side gear
while holding one pinion gear toward the differential case.
Backlash: 0.05 ± 0.20 n nm (0.0020 ± 0.0079 in.)
If the backlash is not within specification, install the side
gear thrust washers of different thickness.
8. CHECK TOTAL PRELOAD
Using a torque wrench, measure the total preload.
Total preload (at starting):
In addition to drive pinion preload
3 ± 5 kg±cm (2.6 ± 4.3 in.±Ib, 0.3 ± 0.5 N±m)
If necessary disassembly and inspect a differential. 7. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the
backlash between the drive pinion and ring gear.
Preload (at staring):
5±8kg±cm (4.3±6.9in.±Ib,0.5±0.8N±n) 5. CHECK TOOTH CONTACT (See page RA±45)
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±34
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DISASSEMBLY OF DIFFERENTIAL
CARRIER
1. REMOVE SIDE GEAR SHAFTS
(a) Remove the two shaft snap rings.
(b) Remove the two side gear shafts.
2. REMOVE SIDE GEAR SHAFT OIL SEALS
Using SST, remove the two oil seals from the housing.
SST 09308±00010
3. REMOVE COMPANION FLANGE
(a) Using a hammer and chisel, loosen the staked part of
the nut.
(b) Using SST to hold the flange, remove the nut.
SST 09330±00021
(c) Remove the plate washer.
(d) Using SST, remove the companion flange.
SST 09557±22022
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±35
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4. REMOVE FRONT OIL SEAL AND OIL SLINGER
(a) Using SST, remove the oil seal from the housing.
SST 09308±10010
(b) Remove the oil slinger.
(c) Using SST, remove the two side bearing preload
adjusting plate.
SST 09504±22011
HINT: Measure the adjusting plate washer and
note the thickness. 5. REMOVE FRONT BEARING AND BEARING SPACER
(a) Using SST, remove the bearing from the housing.
SST 09556±22010
(b) Remove the bearing spacer.
6. REMOVE DIFFERENTIAL CASE
(a) Place matchmarks on the bearing cap and differential
carrier.
(b)Remove the two bearing caps.
(d) Remove the differential case and bearing outer
race from the carrier.
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±36
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8. REMOVE DRIVE PINION REAR BEARING
(a) Using SST and a press, remove the bearing from the
drive pinion.
SST 09950±00020
HINT: If the drive pinion or ring gear are damaged re-
place them a set.
(b) Remove the plate washer.
10. REMOVE RING GEAR
(a) Place the matchmarks on the ring gear and differential
case.
(b) Unstake the lock plates. 9. REMOVE FRONT AND REAR BEARING OUTER RACES
Using a hammer and brass bar, drive out the outer
races from the carrier.HINT: Tag the bearing outer races to show the
location for reassembly.
7. REMOVE DRIVE PINION FROM DIFFERENTIAL
CARRIER
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±37
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(b) Remove the following parts from differential
case:
wPinion shaft
wTwo pinion gears
wTwo side gears
wFour thrust washers
11. REMOVE SIDE BEARINGS
Using SST, remove the two side bearings from differential
case.
SST 09950±24017
12. DISASSEMBLE DIFFERENTIAL CASE
(a) Using a hammer and punch, drive out the straight pin. (d) Using a plastic hammer, tap on the ring gear to sepa-
rate it from differential case. (c) Remove the eight bolts and lock plates.
± REAR AXLE AND SUSPENSIONDifferential (4WD)RA±38