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 SET |
2. 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 |
3. Remove the oil drain plug and oil filler plug.
4. Remove the bolts, and then remove the rear cover.
5. Remove the side retainer attachment bolts, set the ST to differential case, and extract the side retainers RH and LH with a puller.
NOTE:
• Keep the side retainers separate by attaching tags or similar so that the RH and LH sides can be identified when re-assembling them.
• Side retainer shim of each side should be kept together with its mating retainer.
| ST 398457700 | ATTACHMENT |
6. Pull out the differential case assembly from the differential carrier.
NOTE:
Be careful not to hit the teeth of hypoid driven gear against the case while removing.
7. When replacing the side bearing, remove the bearing cup from the side retainer using ST.
| ST 398527700 | PULLER ASSY |
8. Remove the bearing cone with ST.
NOTE:
• Do not attempt to disassemble the parts unless necessary.
• Set the ST so that its claws catch the edge of the bearing cone.
• Never mix up the RH and LH bearing races and cones.
| ST 18759AA000 | PULLER ASSY |
9. Remove the hypoid driven gear by loosening hypoid driven gear bolts.
10. Remove the pinion shaft lock pin from hypoid driven gear side using ST.
| ST 899904100 | STRAIGHT PIN REMOVER |
11. 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 |
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.
|
(A) |
Companion flange |
|
(B) |
Puller |
14. Press the end of drive pinion shaft and extract it together with rear bearing cone, pinion height adjusting washer and washer by using the ST.
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 spacer using the ST.
| ST 398467700 | DRIFT |
|
(A) |
Pilot bearing |
|
(B) |
Spacer |
|
(C) |
Front bearing |
|
(D) |
Rear bearing cup |
18. When replacing the bearings, use a brass bar to tap out the front bearing cup and rear bearing cup (in this order).
|
(A) |
2 cutout portions along diagonal lines |
|
(B) |
Tap alternately with brass bar. |