DISASSEMBLY



caution Do not disassemble the limited slip differential case assembly.




Disassembly steps
<<A>>

·
Inspection before disassembly


1.
Lock plate
<<B>>

2.
Side bearing nut


3.
Bearing cap
<<C>>

4.
Differential case assembly


5.
Differential side bearing outer race
<<D>>

6.
Differential side bearing inner race
<<E>>

7.
Drive gear
<<F>>

8.
Lock pin


9.
Pinion shaft


10.
Pinion gear


11.
Pinion washer


12.
Side gear


13.
Side gear spacer


14.
Differential case


15.
Limited slip differential case assembly
<<G>>

16.
Self-locking nut


17.
Washer
<<H>>

18.
Companion flange
<<H>>

19.
Drive pinion assembly


20.
Drive pinion front shim (For adjusting preload of drive pinion)


21.
Drive pinion spacer
<<I>>

22.
Drive pinion rear bearing inner race


23.
Drive pinion rear shim (for adjusting drive pinion height)


24.
Drive pinion
<<J>>

25.
Oil seal
<<J>>

26.
Drive pinion front bearing inner race
<<J>>

27.
Drive pinion front bearing outer race
<<K>>

28.
Drive pinion rear bearing outer race


29.
Differential carrier




Disassembly steps
<<A>>

·
Inspection before disassembly


1.
Hose


2.
Lock plate
<<B>>

3.
Side bearing nut


4.
Bolt


5.
Bolt


6.
Bearing cap
<<C>>

7.
Differential case assembly


8.
Differential side bearing outer race
<<D>>

9.
Differential side bearing inner race


10.
Actuator assembly


11.
Pressure plate
<<E>>

12.
Drive gear


13.
Differential case


14.
Air pipe assembly (A)


15.
Eye bolt


16.
Air pipe assembly (B)


17.
Gasket


18.
Rear differential lock detection switch


19.
Gasket
<<G>>

20.
Self-locking nut


21.
Washer
<<H>>

22.
Companion flange
<<H>>

23.
Drive pinion assembly


24.
Drive pinion front shim (for adjusting preload of drive pinion)


25.
Drive pinion spacer
<<I>>

26.
Drive pinion rear bearing inner race


27.
Drive pinion rear shim (for adjusting drive pinion height)


28.
Drive pinion
<<J>>

29.
Oil seal
<<J>>

30.
Drive pinion front bearing inner race
<<J>>

31.
Drive pinion front bearing outer race
<<K>>

32.
Drive pinion rear bearing outer race


33.
Differential carrier

DISASSEMBLY SERVICE POINTS



<<A>> INSPECTION BEFORE DISASSEMBLY


Except for the following standard values, inspection procedure is the same as GROUP 26, inspection before disassembly .

    Drive gear backlash
    Standard value:
    0.07 - 0.13 mm <2WD (except High rider)>
    0.08 - 0.18 mm <2WD High rider, 4WD>

<<B>> SIDE BEARING NUT REMOVAL



Use the following special tools, remove the side bearing nut.

  • Special spanner (MB991367)
  • Pin (MB991385)
note Keep the right and left side bearings and side bearing nuts separate, so that they do not become mixed at the time of assembly.

<<C>> DIFFERENTIAL CASE ASSEMBLY REMOVAL


caution When taking out the differential case assembly, be careful not to drop and damage the differential side shims or the side bearing outer races.

Use the wooden handle of a hammer to remove the differential case assembly, differential side shims and side bearings.
note Keep the right and left side bearings and side bearing outer race separated, so that they do not become mixed at the time of assembly.

<<D>> SIDE BEARING INNER RACE REMOVAL



Use the following special tools to pull out the side bearing inner race.

  • Side bearing puller (MB990810)
  • Differential support bush arbour (MB991407)
note Attach the prongs of special tools to the inner race of the side bearing through the openings in the differential case.

<<E>> DRIVE GEAR REMOVAL



1.Make mating marks to the differential case and the drive gear.
2.Loosen the drive gear attaching bolts in diagonal sequence to remove the drive gear.

<<F>> LOCK PIN REMOVAL



Drive out the lock pin with a punch.

<<G>> SELF-LOCKING NUT REMOVAL



Use special tool end yoke holder (MB990850) to hold the companion flange, and then remove the companion flange self-locking nut.

<<H>> DRIVE PINION ASSEMBLY/COMPANION FLANGE REMOVAL


1.
caution Do not make mating marks on the contact surfaces of the companion flange and propeller shaft.
Make mating marks to the drive pinion and companion flange.

2.Use special tool side bearing puller (MB990810) to pull out the companion flange.

<<I>> DRIVE PINION REAR BEARING INNER RACE REMOVAL



Use special tool remover (MD998801) to pull out the front bearing inner race.

<<J>> OIL SEAL/DRIVE PINION FRONT BEARING INNER RACE/DRIVE PINION FRONT BEARING OUTER RACE REMOVAL



Use special tool brass bar (MB990939) to remove the drive pinion front bearing outer race.

<<K>> DRIVE PINION REAR BEARING OUTER RACE REMOVAL



Use special tool brass bar (MB990939) to remove the drive pinion rear bearing outer race.