4-1

DIFFERENTIAL
Page
GENERAL...............................................................4-2
0
SPECIFICATIONS ..................................................4-5
1
COMPONENTS ......................................................4-6
2
DIFFERENTIAL ASSY ...........................................4-9
REMOVAL·INSTALLATION (DRY BRAKE MODEL) .....4-9
3
REMOVAL·INSTALLATION 4
(WET BRAKE MODEL) .........................................4-12
5
DISASSEMBLY·INSPECTION·REASSEMBLY
(1·2·K2 TON SERIES) ...........................................4-15 6
DISASSEMBLY·INSPECTION·REASSEMBLY 7
(3·J3.5 TON SERIES)............................................4-21
DIFFERENTIAL CASE ASSY ..............................4-28 8
DISASSEMBLY·INSPECTION·REASSEMBLY 9
(1·2·K2 TON SERIES) ...........................................4-28
10
DISASSEMBLY·INSPECTION·REASSEMBLY
(3·J3.5 TON SERIES)............................................4-32 11
12
13
14
15
16
17
18
19
20
21
E
4-2

GENERAL
Differential (1·K2 Ton Series)

Differential (2 Ton Series)

 4-3

Differential (3·J3.5 Ton Series)

0
1
2
3
4
5
6
7
8
9
10
Reduction Gear (1·K2 Ton Series)
11
12
13
14
15
16
17
18
19
20
21
E
4-4

Reduction Gear (2 Ton Series)

Reduction Gear (3·J3.5 Ton Series)

 4-5

SPECIFICATIONS
Vehicle model
1·K2 ton series 2 ton series 3·J3.5 ton series
Item
← ←
Differential case type
Reduction ratio (ring gear/drive pinion)
Banjo type
5.833 ← ←
0
Differential

Number of teeth
Drive pinion
Ring gear
6
35
←
←
←
←
1
Number of teeth × Pinion gear
quantity
11 × 2 10 × 2 10 × 4
2
Side gear 16 × 2 ← 14 × 2
Differential oil quantity Dry brake model 5.5 ~ 6.1 (1.45 ~ 1.61) 5.8 ~ 6.4 (1.53 ~ 1.69) 7.8 ~ 8.6 (2.06 ~ 2.27) 3
l (US gal) Wet brake model (OPT) —— 6.1 ~ 6.7 (1.61 ~ 1.77) 8.0 ~ 8.8 (2.11 ~ 2.32)
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
4-6

COMPONENTS
1·K2 ton series

4101
AG
02

40 BD

AF
FV 40C AB
48A
CT
AF
48

47
AB
EW
46A 40
20
46 20A
20B
48 CN
48A 46
46A

10A CN
61 49A
49
10D
AS 10E 12
CL 02
10C 20B
20A
55

DY

60A[NO.2]
60
60A[NO.1]
59 AH 59A GU

4101-231

2 ton series

4101
02
AG

40 BD
FV
48A AF AB

48 40C AF
CT
47

46A
20 EW
46 AB
48 20A
40
20B 12
48A 46
CN
46A

CN 49A
49
10A
61
10D
10E
AS AL
CL
10C 02 20B
55 20A

DY
60A[NO.2]
60
60A[NO.1]
GU
59 AH 59A
4101-239
 4-7

3·J3.5 ton series

4101
02
AG

40
BD

48A
46A 48 AF AB
48A
46 48 40C
CT
AF

47
48
20 AB
48A 20A EW
48 40
20B
CN
48A 46 10B
46A

FP
49A
10A CN 49
50
61

AS 10D
10E 12
CL
10C 02 20B
20A
55

DY 60A[NO.2]
60
60A[NO.1]
GU
AH 59A 4101-240
59
4-8

2 ton series (Wet brake model)

4101

3·J3.5 ton series (Wet brake model)

4101
 4-9

DIFFERENTIAL ASSY
REMOVAL·INSTALLATION (DRY BRAKE MODEL)
Note:
Never apply impact to the frame at the time of removal or installation to protect the controller from damage.
T = N·m (kgf·cm) [ft·lbf]

17

17 16

16
12 17
8
8
17 13 6
21
*3

*2
20
*4 *4
18 19
*2
20
5

19 *1

*1

1·2 ton series, K2 ton series T = 68.6 ~ 98.0 (700 ~ 1000) [50.6 ~ 72.3]
*1 Axle shaft set bolt
3 ton series, J3.5 ton series T = 107 ~ 140 (1100 ~ 1400) [78.9 ~ 103.3]
1·2 ton series, K2 ton series T = 108 ~ 159 (1100 ~ 1600) [79.7 ~ 117.3]
*2 Front axle ASSY set bolts
3 ton series, J3.5 ton series T = 127 ~ 190 (1300 ~ 1900) [93.4 ~ 140.2]
*3 Bolt T = 294 ~ 343 (3000 ~ 3500) [216.9 ~ 253.1]
*4 Front axle bracket set nut T = 235 ~ 294 (2400 ~ 3000) [173.4 ~ 216.9]
4-10

Removal Procedure
1 Remove the mast. (Refer to page 11-5)
2 Remove the lower panel and toe board.
3 Remove the instrument panel.
4 Drain differential oil. [Point 1]
5 Jack up the vehicle and remove the front wheel.
6 Remove the speed sensor cover, and disconnect the connector.
7 Drain brake fluid, and disconnect the brake pipe (wheel cylinder side).
8 Disconnect the parking brake cable (lever side).
9 Remove the parking brake cable clamp.
10 Disconnect the mount insulator link.
11 Remove the under cover and propeller shaft cover.
12 Disconnect the propeller shaft. (Refer to page 3-5)
13 Support the bottom of the transmission with a pantograph jack or wooden block.
14 Support the front axle & differential ASSY with a hoist or garage jack. [Point 2]
15 Remove the connector bracket.
16 Remove the front axle bracket through bolts.
17 Remove the front axle bracket reamer bolt. [Point 3]
18 Remove the front axle & differential ASSY.
19 Remove the front axle shaft. (Refer to page 5-9) [Point 4]
20 Remove the front axle W/ bracket. (Refer to page 5-13)
21 Remove the speed sensor.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• After reassembly, bleed air from the brake. (Refer to 8-22)
• After reassembling the parking brake cable, inspect and adjust the parking brake. (Refer to page 8-26)

Point Operations
[Point 1]
Installation:
After installation, add hypoid gear oil to the specified level.
Vehicle model A
A 1·K2 ton series 1.7 ~ 12.0 mm (0.07 ~ 0.47 in)
2 ton series 1.4 ~ 11.8 mm (0.06 ~ 0.46 in)
3·J3.5 ton series 1.2 ~ 13.8 mm (0.05 ~ 0.54 in)
 4-11

[Point 2]
Removal•Installation:
Install hub nuts on hub bolts on the left and right sides, and
sling wire at the tapered portion.

[Point 3]
SST Removal:
SST 09310-23320-71

[Point 4]
Removal•Installation:
Operate carefully so as not to bring the axle shaft into contact
with the oil seal lip to damage it.
4-12

REMOVAL·INSTALLATION (WET BRAKE MODEL)

Note:
• Never apply impact to the frame at the time of removal or installation to protect the controller from
damage.
• Release the pressure from the accumulator before starting operation. (Refer to page 8-48)
T = N·m (kgf·cm) [ft·lbf]

17 17
16
17
12 17
16
12
*3 7
17 8
22

13 6
19
*2
21
*4 *4
18 20
*2 21
6

20
*1

*1

2 ton series T = 68.6 ~ 98.0 (700 ~ 1000) [50.6 ~ 72.3]

*1 Axle shaft set bolt
3·J3.5 ton series T = 107 ~ 140 (1100 ~ 1400) [78.9 ~ 103.3]
2 ton series T = 108 ~ 159 (1100 ~ 1600) [79.7 ~ 117.3]
*2 Front axle ASSY set bolts
3·J3.5 ton series T = 127 ~ 190 (1300 ~ 1900) [93.4 ~ 140.2]
*3 Bolt T = 294 ~ 343 (3000 ~ 3500) [216.9 ~ 253.1]
*4 Front axle bracket set nut T = 235 ~ 294 (2400 ~ 3000) [173.4 ~ 216.9]
 4-13

Removal Procedure
1 Remove the mast. (Refer to page 11-5)
2 Drain brake cooling oil in ASSY. (Refer to page 8-64)
3 Remove the lower panel and toe board.
4 Remove the instrument panel.
5 Drain differential oil. [Point 1]
6 Jack up the vehicle and remove the front wheel.
7 Remove the speed sensor cover, and disconnect the connector.
8 Disconnect the parking brake cable (unit side).
9 Support the bottom of the transmission with a pantograph jack or wooden block.
10 Disconnect the mount insulator link.
11 Disconnect the propeller shaft. (Refer to page 3-6)
12 Remove the 3-way and disconnect each pipe.
13 Remove the accumulator ASSY. (Refer to page 8-55)
14 Support the front axle & differential ASSY with a hoist or garage jack. [Point 2]
15 Remove the connector bracket.
16 Remove the front axle bracket through bolts.
17 Remove the front axle bracket reamer bolt. [Point 3]
18 Remove the front axle & differential ASSY.
19 Remove the parking brake ASSY. (Refer to page 8-58)
20 Remove the front axle shaft. (Refer to page 5-20) [Point 4]
21 Remove the front axle W/ bracket. (Refer to page 5-25)
22 Remove the speed sensor.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• After reassembly, bleed air from the brake. (Refer to page 8-48)
• After reassembly, check the operation of the accumulator. (Refer to page 8-57)
• After reassembling the parking brake cable, inspect and adjust the parking brake. (Refer to page 8-61, 62)

Point Operations
[Point 1]
Installation:
After installation, add hypoid gear oil to the specified level.
Vehicle model A
A 2 ton series 1.4 ~ 9.5 mm (0.06 ~ 0.37 in)
3·J3.5 ton series 1.2 ~ 11.8 mm (0.05 ~ 0.46 in)
4-14

[Point 2]
Removal•Installation:
Install hub nuts on hub bolts on the left and right sides, and
sling wire at the tapered portion.

[Point 3]
Removal:
SST 09310-23320-71

SST

[Point 4]
Removal•Installation:
Operate carefully so as not to bring the axle shaft into contact
with the oil seal lip to damage it.
 4-15

DISASSEMBLY·INSPECTION·REASSEMBLY (1·2·K2 TON SERIES)

T = N·m (kgf·cm) [ft·lbf]

12

3 2

T = 6.9 ~ 16.1
T = 17.3 ~ 21.7 (70.4 ~ 164.2)
(176 ~ 221) [5.0 ~ 11.9]
[12.8 ~ 16.0] T = 343 ~ 392 T = 117.7 ~ 137.3
(3500 ~ 4000) (1200 ~ 1400)
4
[253.1 ~ 289.2] [86.8 ~ 101.3]

5
T = 32.4 ~ 48.6
T = 13.5 ~ 24.5
7 (330 ~ 496)
(138 ~ 250)
[23.9 ~ 35.9]
[10.0 ~ 18.1]

14
13
6

10

10
8 9
11
4-16

Removal Procedure
1 Remove the differential cover. [Point 1]
2 Remove the bearing cap and adjusting nut. [Point 2]
3 Remove the differential case ASSY.
4 Remove the drive pinion rear cover.
5 Remove the lock nut. [Point 3]
6 Remove the input shaft.
7 Remove the drive pinion W/ bearing. [Point 4]
8 Remove the output gear and reduction gear W/ carrier cover. [Point 5]
9 Remove the reduction gear W/ bearing. [Point 6]
10 Remove the reduction gear bearing.
11 Remove the output gear.
12 Remove the drive pinion outer race. [Point 7]
13 Remove the oil seal. [Point 8]
14 Remove the input shaft dust deflector. [Point 9]

Installation Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Reassembly:
Apply sealing agent (Three Bond’s 1217C or equivalent
products) to the surfaces to be contact with the differential
cover and differential housing, and reassemble.

[Point 2]
Disassembly:
Make match marks on the bearing cap and differential housing.
Reassembly:
Reassemble the adjusting nut and bearing cap in the following procedure.
1. Install the adjusting nut.
2. Align the match marks to install the bearing cap, and
temporarily tighten the set bolt.
T = 19.6 N·m (200 kgf·cm) [14.5 ft·lbf]
Match marks

3. Set a dial gauge at the back of the ring gear, and tighten the
adjusting nut.
4. Using the SST, tighten until the thrust clearance becomes 0.
SST 09630-10110-71
5. Tighten the adjusting nuts on both sides by one notch.
6. Set a dial gauge perpendicular to the tooth face of the ring
gear, and measure the backlash.
 4-17

Standard: 0.2 ~ 0.3 mm (0.008 ~ 0.012 in)

SST If the standard is not met, adjust by moving the differential
case ASSY to the thrust direction with the adjusting nut.
(1) When the backlash is excessive.
Loosen the adjusting nut on the ring gear tooth face side,
and tighten the adjusting nut on the back side by the
same amount in order to move the ring gear closer to the
drive pinion.
(2) When the backlash is insufficient.
Loosen the adjusting nut on the back side of the ring gear,
and tighten the adjusting nut on the tooth face side by the
same amount in order to move the ring gear away from
the drive pinion.
7. Further tighten the adjusting nut on the ring gear tooth face
side by 1.5 to 2 notches.
8. Install the adjusting nut lock plate.
9. Fully tighten the bearing cap set bolt.
T = 117.7 ~ 137.3 N·m (1200 ~ 1400 kgf·cm)
[86.82 ~ 101.3 ft·lbf]

[Point 3]
Disassembly:
Remove the lock nut, washer and shim.
1. Unstake the lock nut.
2. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
3. Remove the lock nut and washer.

Reassembly:
Reassemble the shim, rear bearing roller, washer and lock nut
Deep groove
in the following procedure.
1. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
Claw (pawl)
2. While supporting the drive pinion, reassemble the shim, rear
bearing and washer with its claw (pawl) lining up with the deep
groove.
Shim Also, in order to avoid shock contact between the rear bearing
roller and rear bearing outer race, reassmble the rear bearing
by tightening the lock nut.
3. Tighten the lock nut to the temporarily specified torque.
T = 157 ~ 235 N·m (1600 ~ 2400 kgf·cm) [115.8 ~ 173.4 ft·lbf]
4. Remove the input shaft.
5. Using a wrench, turn the gear five times.
6. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
4-18

7. Tighten the lock nut again to the specified torque.

T = 343 ~ 392 N·m (3500 ~ 4000 kgf·cm) [253.1 ~ 289.2 ft·lbf]
8. Remove the input shaft.
9. Using a wrench, turn the gear ten times.
10. Measure the drive pinion starting torque.
Standard
1·K2 ton series: 8.5 ~ 13.0 N·m (90 ~ 135 kgf·cm)
[6.3 ~ 9.6 ft·lbf]
2 ton series: 8.5 ~ 15.0 N·m (90 ~ 155 kgf·cm)
[6.3 ~ 11.1 ft·lbf]
If the standard is not met, adjust by changing the thickness of
the shim.
Thickness of the shim:
0.1·0.13·0.15·0.32·0.35·0.4·0.5·0.59 mm
[0.0039·0.0051·0.0059·0.013·0.014·0.016·0.020·0.023 in]

11. Firmly stake the lock nut.

Good
example

1 mm (0.039 in) or less

Bad example

[Point 4]
Disassembly:
Remove the drive pinion W/ bearing.
1. Insert a wooden block inside the differential housing in order to
prevent damage to the drive pinion.
2. Using a plastic hammer, remove the drive pinion W/ bearing.

Disassembly:
Remove the bearing inner race using the SST and a press.
SST 09420-23002-71
SST
 4-19

Reassembly:
Install the bearing inner race using the SST and a press.
SST 1 ton series·K2 ton series:
SST 09316-76008-71
(09316-60011)
2 ton series:
SST 09410-26600-71

[Point 5]
Reassembly:
Check the reassembly direction of the output gear and
reduction gear.

Reassembly:
Apply sealing agent (08826-76002-71 (08826-00090)) to the
surface to be in contact with the differential carrier cover, and
reassemble.

[Point 6]
SST(2)
Disassembly:
SST(1) Remove the reduction gear bearing using the SST and a
press.
SST 09950-76018-71................................. (1)
(09950-60010)
SST(3) 09950-76020-71................................. (2)
(09950-70010)
09420-23002-71................................. (3)

Reassembly:
Reassemble the reduction gear bearing using the SST and a
SST(2) press.
SST(1) SST 09950-76018-71................................. (1)
(09950-60010)
09150-76020-71................................. (2)
(09950-70010)
4-20

[Point 7]
SST(2)
Disassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
09150-76020-71................................. (2)
(09950-70010)

SST(1)

Reassembly:
SST(2) SST 09950-76018-71................................. (1)
SST(1)
(09950-60010)
09150-76020-71................................. (2)
(09950-70010)

[Point 8]
A
Reassembly:
Using a pin, tap new oil seal in from the edge of the differential
carrier cover to the depth shown by A.
A = 5.0 ~ 5.5 mm [0.20 ~ 0.22 in]
After reassembly, apply MP grease to the lip section of the oil
seal.

[Point 9]
Reassembly:
Using the SST, reassemble the input shaft dust deflector.
SST 09370-20270-71

SST
 4-21

DISASSEMBLY·INSPECTION·REASSEMBLY (3·J3.5 TON SERIES)

T = N·m (kgf·cm) [ft·lbf]

13

15

3 2
14

T = 13.5 ~ 24.5
(138 ~ 250)
[10.0 ~ 18.1]

T = 343 ~ 392 T = 6.9 ~ 16.1

(3500 ~ 4000) (70.4 ~ 164.2)
4 [253.1 ~ 289.2] [5.0 ~ 11.9]
T = 117.7 ~ 137.3
(1200 ~ 1400)
5 [86.8 ~ 101.3]
6
T = 32.4 ~ 48.6
15 (330 ~ 496)
[23.9 ~ 35.9]

T = 17.3 ~ 21.7 T = 54.2 ~ 75.3

(176 ~ 221) (553 ~ 768)
[12.8 ~ 16.0] [40.0 ~ 55.6] 12

13
17

16
7

10
11
10

8
9
4-22

Disassembly Procedure
1 Remove the differential cover. [Point 1]
2 Remove the bearing cap and adjusting nut. [Point 2]
3 Remove the differential case ASSY.
4 Remove the drive pinion rear cover.
5 Remove the lock nut. [Point 3]
6 Remove the drive pinion outer bearing roller.
7 Remove the input shaft.
8 Remove the output gear and reduction gear W/ carrier cover. [Point 4]
9 Remove the reduction gear W/ bearing. [Point 5]
10 Remove the reduction gear bearing.
11 Remove the output gear.
12 Remove the drive pinion bearing retainer.
13 Remove the drive pinion W/ pilot bearing. [Point 6]
14 Remove the pilot bearing. [Point 7]
15 Remove the drive pinion bearing outer race. [Point 8]
16 Remove the oil seal. [Point 9]
17 Remove the input shaft dust deflector. [Point 10]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Reassembly:
Apply sealing agent (Three Bond’s 1217C or equivalent
products) to the surfaces to be contact with the differential
cover and differential housing, and reassemble.

[Point 2]
Disassembly:
Make match marks on the bearing cap and differential
housing.
Reassembly:
Reassemble the adjusting nut and bearing cap in the following
procedure.
1. Install the adjusting nut.
Match marks 2. Align the match marks to install the bearing cap, and
temporarily tighten the set bolt.
T = 19.6 N·m (200 kgf·cm) [14.5 ft·lbf]
 4-23

3. Set a dial gauge at the back of the ring gear, and tighten the
adjusting nut.
4. Using the SST, tighten until the thrust clearance becomes 0.
SST 09630-10110-71
5. Tighten the adjusting nuts on both sides by one notch.
6. Set a dial gauge perpendicular to the tooth face of the ring
gear, and measure the backlash.

Standard
SST 0.3 ~ 0.4 mm [0.012 ~ 0.016 in]
If the standard is not met, adjust by moving the differential
case ASSY to the thrust direction with the adjusting nut.
(1) When the backlash is excessive.
Loosen the adjusting nut on the ring gear tooth face side,
and tighten the adjusting nut on the back side by the
same amount in order to move the ring gear closer to the
drive pinion.
(2) When the backlash is insufficient.
Loosen the adjusting nut on the back side of the ring gear,
and tighten the adjusting nut on the tooth face side by the
same amount in order to move the ring gear away from
the drive pinion.
7. Further tighten the adjusting nut on the ring gear tooth face
side by 1.5 to 2 notches.
8. Install the adjusting nut lock plate.
9. Fully tighten the bearing cap set bolt.
T = 117.7 ~ 137.3 N·m (1200 ~ 1400 kgf·cm)
[86.82 ~ 101.3 ft·lbf]

[Point 3]
Disassembly:
Remove the lock nut, washer and shim.
1. Unstake the lock nut.
2. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
3. Remove the lock nut and washer.
4-24

Reassembly:
Reassemble the shim, rear bearing roller, washer and lock nut
Deep groove
in the following procedure.
1. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
Claw (pawl)
2. While supporting the drive pinion, reassemble the shim, rear
bearing and washer with its claw (pawl) lining up with the deep
groove.
Shim Also, in order to avoid shock contact between the rear bearing
roller and rear bearing outer race, reassemble the rear bearing
by tightening the lock nut.
3. Tighten the lock nut to the temporarily specified torque.
T = 157 ~ 235 N·m (1600 ~ 2400 kgf·cm) [115.8 ~ 173.4 ft·lbf]
4. Remove the input shaft.
5. Using a wrench, turn the gear five times.
6. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.

7. Tighten the lock nut again to the specified torque.

T = 343 ~ 392 N·m (3500 ~ 4000 kgf·cm) [253.1 ~ 289.2 ft·lbf]
8. Remove the input shaft.
9. Using a wrench, turn the gear ten times.
10. Measure the drive pinion starting torque.
Standard: 8.5 ~ 13.0 N·m (90 ~ 135 kgf·cm) [6.3 ~ 9.6 ft·lbf]
If the standard is not met, adjust by changing the thickness of
the shim.
Thickness of the shim:
0.1·0.13·0.15·0.32·0.35·0.4·0.5·0.59 mm
[0.0039·0.0051·0.0059·0.013·0.014·0.016·0.02·0.023 in]

Good
11. Firmly stake the lock nut.
example

1 mm (0.039 in)
or less

Bad example
 4-25

[Point 4]
Reassembly:
Apply sealing agent (08826-76002-71 (08826-00090)) to the
surface to be in contact with the differential carrier cover, and
reassemble.

[Point 5]
Reassembly:
Check the reassembly direction of the output gear and
reduction gear.

Disassembly:
SST(2)
Remove the reduction gear bearing using the SST and a
SST(1) press.
SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
SST(3) 09420-23002-71................................. (3)

Reassembly:
Reassemble the reduction gear bearing using the SST and a
SST(2) press.
SST(1) SST 09950-76018-71................................. (1)
(09950-60010)
09150-76020-71................................. (2)
(09950-70010)

[Point 6]
SST(2)
Disassembly:
SST 09950-76018-71................................. (1)
SST(1) (09950-60010)
09150-76020-71................................. (2)
(09950-70010)
4-26

SST(2) Disassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
09150-76020-71................................. (2)
(09950-70010)
SST(1)

[Point 7]
Disassembly:
SST 09950-76014-71
SST (09950-40011)

Reassembly:
Reassemble the pilot bearing using the SST and a press.
SST 09608-76003-71
SST (09608-04031)
After reassembling the pilot bearing, stake three places at the
end of the drive pinion.
Check the reassembly direction.

Disassembly:
Remove the bearing inner race using the SST and a press.
SST SST 09420-23002-71

Reassembly:
Reassemble the bearing inner race using the SST and a
press.
SST
SST 09316-76008-71
(09316-60011)
 4-27

[Point 8]
Disassembly:

SST(2)
SST 09950-76018-71................................. (1)
(09950-60010)
09150-76020-71................................. (2)
(09950-70010)
SST(1)

Disassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
SST(2) 09150-76020-71................................. (2)
(09950-70010)

SST(1)

[Point 9]
A
Reassembly:
Using a pin, tap new oil seal in from the edge of the differential
carrier cover to the depth shown by A.
A = 5.0 ~ 5.5 mm [0.20 ~ 0.22 in]
After reassembly, apply MP grease to the lip section of the oil
seal.

[Point 10]
Reassembly:
Using the SST, reassemble the input shaft dust deflector.
SST 09370-20270-71

SST
4-28

DIFFERENTIAL CASE ASSY

DISASSEMBLY·INSPECTION·REASSEMBLY (1·2·K2 TON SERIES)
T = N·m (kgf·cm) [ft·lbf]

4 3

2
4

T = 127.4 ~ 176.4
(1300 ~ 1800) 1
[94.0 ~ 130.1]

Disassembly Procedure
1 Remove the side bearing. [Point 1]
2 Remove the ring gear. [Point 2]
3 Remove the pinion shaft pin. [Point 3]
4 Remove the side gear and pinion gear. [Point 4]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
 4-29

Point Operations
[Point 1]
SST(1) Disassembly:
SST 09950-76014-71................................. (1)
SST(2) (09950-40011)
09950-76018-71................................. (2)
(09950-60010)

Reassembly:
Install the side bearing.
SST(2) 1. Reassemble the side bearing to the edge of the case using the
SST and a press.
SST(1)
SST 09950-76019-71................................. (1)
(09950-60020)
09950-76020-71................................. (2)
(09950-70010)
2. Fully tap the side bearing in by using a striking driver.

[Point 2]
Reassembly:
Apply thread tightener (08833-76001-71 (08833-00070)) to the
threaded portion of the set bolts. Gradually tighten them in the
diagonal order, and finally tighten to the specified torque in the
circular order.

[Point 3]
Disassembly:
Unstake the differential case pin hole, and punch out the pin
using the SST.
SST SST 09411-13330-71

Reassembly:
Tap the pin in the differential case pin hole using SST until it
contacts the stepped section.
Reference value: A = 5 mm (0.20 in)
SST A
Tap the pin in with the chamfer side facing down.
SST 09411-13330-71

Chamfer
4-30

C C View After tapping, stake the differential case pin hole with a chisel.
Check that the staking allowance is B in the illustration = 1 mm
(0.039 in) or more, and there should be no cracks.
Pin
After staking, check that the gear rotates smoothly.

[Point 4]
Inspection:
Measure the differential pinion inside diameter.
Standard
1·K2 ton series: 26.12 mm (1.028 in)
2 ton series: 28.12 mm (1.107 in)
Limit
1·K2 ton series: 26.22 mm (1.032 in)
2 ton series: 28.22 mm (1.111 in)

Inspection:
Measure the outside diameter of the pinion shaft.
Standard
1·K2 ton series: 26.00 mm (1.024 in)
2 ton series: 28.00 mm (1.102 in)
Limit
1·K2 ton series: 25.75 mm (1.014 in)
2 ton series: 27.75 mm (1.093 in)

Inspection:
Measure the thickness of the side gear thrust washer.
Standard: 1.6 mm (0.063 in)
Limit: 1.3 mm (0.051 in)
Inspection:
Measure the thickness of the pinion thrust washer.
Standard
1·K2 ton series: 1.0 mm (0.039 in)
2 ton series: 1.6 mm (0.063 in)
Limit
1·K2 ton series: 0.7 mm (0.028 in)
2 ton series: 1.3 mm (0.051 in)
 4-31

Reassembly:
Grease application Reassemble the pinion thrust washer after evenly applying
chassis grease special on both sides.

Reassembly:
Reassembling procedures are as follows.
1. Reassemble the side gear and pinion to the differential case.
2. Turn the pinion to the pinion shaft hole.

3. Reassemble the pinion shaft.

4-32

DISASSEMBLY·INSPECTION·REASSEMBLY (3·J3.5 TON SERIES)

T = N·m (kgf·cm) [ft·lbf]

4
1

T = 86.2 ~ 102.9
(879 ~ 1049)
[63.6 ~ 75.9]

T = 127.4 ~ 176.4
(1300 ~ 1800)
[94.0 ~ 130.1]

Disassembly Procedure
1 Remove the differential case bearings. [Point 1]
2 Remove the differential upper case. [Point 2]
3 Remove the side gear and pinion gear. [Point 3]
4 Remove the ring gear. [Point 4]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
 4-33

Point Operations
[Point 1]
SST(1) Disassembly:
SST 09950-76014-71................................. (1)
SST(2)
(09950-40011)
09950-76018-71................................. (2)
(09950-60010)

Reassembly:
Install the side bearing.
SST(2) 1. Use the SST to drive in the side bearing to the end surface.
SST(1) SST 09950-76019-71................................. (1)
(09950-60020)
09950-76020-71................................. (2)
(09950-70010)
2. Use a striking driver to fully drive in the bearing.

[Point 2]
Disassembly•Reassembly:
Check the match marks.
Reassembly:
Apply locking agent (08833-76001-71 (08833-00070)) on the
set bolt threaded portion before reassembly.

Match marks

[Point 3]
Inspection:
Measure the inside diameter of the differential pinion.
Standard: 24.67 mm (0.971 in)
Limit: 24.77 mm (0.975 in)

Inspection:
Measure the spider outside diameter.
Standard: 24.50 mm (0.965 in)
Limit: 24.25 mm (0.955 in)
4-34

Inspection:
Measure the side gear thrust washer thickness.
Standard: 1.6 mm (0.063 in)
Limit: 1.3 mm (0.051 in)
Inspection:
Measure the pinion gear thrust washer thickness.
Standard: 1.6 mm (0.063 in)
Limit: 1.0 mm (0.039 in)

Reassembly:
Install the side gear thrust washer with its oil groove facing the
gear.

Reassembly:
Grease application Apply chassis grease (molybdenum disulfide grease) on both
sides of the spider pinion thrust washer before reassembly.

[Point 4]
Reassembly:
Apply locking agent (08833-76001-71 (08833-00070)) on the
set bolt threaded portion before reassembly. Tighten the set
bolts gradually in the diagonal order, and finally tighten in the
circular order to the specified torque.