To detect the real cause of trouble, inspect the following items before disassembling.
• Tooth contact and backlash between hypoid driven gear and drive pinion
• 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.
• Whenever the air breather cap is removed, replace it with a new part.
|
(A) |
Air breather cap |
|
(B) |
Rear cover |
4. Remove the bolts, and then remove the rear cover.
NOTE:
Remove it by tapping with a plastic hammer.
|
(A) |
Rear cover |
|
(B) |
Differential carrier |
5. Keep the side bearing retainers separate to make it possible to identify RH and LH sides. 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 so that the teeth do not hit against the case.
7. Remove the O-rings from the side bearing retainer.
8. Remove the oil seal from the side bearing retainer. 
9. When replacing the side bearing, remove the bearing cup from the side bearing retainer using ST.
| 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.
• Store so that the right and left side bearing races and cones are not mixed together.
| ST 18759AA000 | PULLER ASSY |
11. Remove the hypoid driven gear by loosening hypoid driven gear bolts.
12. Remove the self-locking nut while holding the companion flange with ST.
| ST 498427200 | FLANGE WRENCH |
13. Extract the companion flange with a puller.
14. 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 |
15. 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 |
16. Remove the front oil seal from differential carrier using ST.
| ST 398527700 | PULLER ASSY |
|
(A) |
Differential carrier |
|
(B) |
Front oil seal |
17. Remove the pilot bearing together with the front bearing cone and collar using the ST.
| ST 398467700 | DRIFT |
|
(A) |
Pilot bearing |
|
(B) |
Collar |
|
(C) |
Front bearing |
|
(D) |
Rear bearing cup |
18. When replacing the bearings, hit out the front bearing cup and rear bearing cup in this order out of case using a brass bar.
|
(A) |
2 cutout portions along diagonal lines |
|
(B) |
Tap alternately with brass bar. |