Rear Differential Disassembly

Reference: REAR DIFFERENTIAL DISMOUNTING AND REMOUNTING: REAR 

1. Hold differential assembly securely and put identification marks (A) on differential side bearing caps (6).
2. Take off differential side bearing lock plates (4) and differential side bearing caps (6) by removing their bolts and then take out bearing adjusters (5), side bearing outer races and drive bevel gear assembly (2) with differential case (3).
   Fig 1: Identifying Differential Side Bearing Lock Plates, Side Bearing Caps, Bearing Adjusters, Drive Bevel Gear Assembly, Differential Case And Differential Carrier

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3. With aluminum plates (2) placed on vise first, grip differential case with it and remove drive bevel gear (hypoid gear) (3) by removing its bolts (1).
   Fig 2: Identifying Differential Case Bolts, Drive Bevel Gear & Aluminum Plates

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4. Remove differential left case (2) from differential right case (1).
   Fig 3: Identifying Differential Left Case & Differential Right Case

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5. Remove pinion shafts, differential gears, washers, differential pinions, spring washers, thrust washers.
   Fig 4: Identifying Differential

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6. Using special tools, pull out differential side bearings (1).

   Special Tool 

   (C): 09913-85230 

   (D): 09913-61510 

   Fig 5: Identifying Differential Side Bearings & Special Tools

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7. Remove drive bevel pinion (hypoid gear) assembly.
   1. Hold joint flange with special tool and then remove flange nut by using power wrench (4 - 10 magnification) (2).

      Special Tool 

      (E): 09922-66021 

      Fig 6: Identifying Power Wrench, Socket Wrench & Special Tool

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   2. Make mating marks (1) on drive bevel pinion and companion flange.
      CAUTION: Do not make mating mark on the coupling surface of the flange.
   3. Remove companion flange from drive bevel pinion. Use special tool if it is hard to remove.

      Special Tool 

      (F): 09913-65135 

      Fig 7: Identifying Mating Marks & Special Tool

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   4. Remove drive bevel pinion with rear bearing, shim and spacer from carrier.

      If it is hard to remove, screw an used nut into drive bevel pinion and hammer on that nut with a plastic hammer but never directly on drive bevel pinion.

      Fig 8: Removing Drive Bevel Pinion With Plastic Hammer

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   5. Remove drive bevel pinion rear bearing (2) by using bearing puller (3) and hydraulic press.
      Fig 9: Identifying Drive Bevel Pinion Rear Bearing, Drive Bevel Pinion And Puller

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8. Using a hammer and brass bar (1), drive out front bearing outer race with bearing (2) and oil seal (3).
   Fig 10: Identifying Brass Bar, Bearing & Oil Seal

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9. Drive out rear bearing outer race in the same way as in the Step  6.
   Fig 11: Driving Out Rear Bearing Outer Race

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