To detect the real cause of trouble, inspect the following items before disassembling.
• Tooth contact and backlash between the 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 SET |
2. Remove the oil drain plug and filler plug, and drain the gear oil.
3. Remove the rear cover by removing retaining bolts.
NOTE:
Remove it by tapping with a plastic hammer.
4. 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 |
5. Remove the lock plate RH and LH.
6. Remove the side retainer RH and LH with ST.
| ST 18630AA010 | WRENCH COMPL RETAINER |
7. Pull out the differential case assembly from differential carrier.
NOTE:
Be careful not to hit the teeth against the case.
8. Remove the bearing race from side retainer RH and LH with ST1 and ST2.
| ST1 499705401 | PULLER ASSY |
| ST2 499705404 | SEAT |
|
(A) |
Bearing race |
|
(B) |
Side retainer |
9. Remove the oil seal from the RH and LH side retainers using a screwdriver.
NOTE:
Perform this operation only when changing oil seal.
10. Extract the bearing cone with ST1 and ST2.
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.
| ST1 899524100 | PULLER SET |
| ST2 399520105 | SEAT |
11. Remove the hypoid driven gear by loosening hypoid driven gear bolts.
12. Drive out the pinion shaft lock pin from the hypoid driven gear side.
NOTE:
The lock pin is staked at the pin hole end on the differential case. 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.
NOTE:
The gears should be marked or kept separated right and left, and front and rear as well as thrust washers.
|
(A) |
Side gear |
|
(B) |
Pinion mate gear |
|
(C) |
Thrust washer |
|
(D) |
Differential case |
|
(E) |
Pinion mate shaft |
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.
|
(A) |
Companion flange |
|
(B) |
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 498515500 | REPLACER |
18. Remove the front oil seal from differential carrier using ST.
| ST 398527700 | PULLER ASSY |
|
(A) |
Differential carrier |
|
(B) |
Front oil seal |
19. Remove the pilot bearing together with the front bearing cone and spacer using the ST.
| ST 398467700 | DRIFT |
|
(A) |
Pilot bearing |
|
(B) |
Spacer |
|
(C) |
Front bearing |
|
(D) |
Rear bearing cup |
20. When replacing the bearings, hit out the front bearing cup and rear bearing cup in this order using a brass bar.
|
(A) |
2 cutouts along diagonal lines |
|
(B) |
Tap alternately with brass bar. |