Disassembly [12/2019 - ]: Procedure

1. Remove the 4 bolts and differential disconnect cover from the rear differential carrier assembly.

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1. Disconnect the 4 connectors.

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   	Bolt
   	Connector

2. Remove the bolt.
3. Disengage the 4 clamps to remove the clutch control solenoid wire.

1. Remove the 3 bolts and 3 wire harness clamp brackets from the rear differential carrier assembly.

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2. Disengage the clamp to disconnect the wire harness.
   NOTE:

   Do not damage the wire harness.

1. Remove the bolt and transmission revolution sensor from the rear differential carrier assembly.

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2. Remove the O-ring.

See step  2

1. Cut the clutch control solenoid wire as shown in the illustration.

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   *a	Cut Area
   	Bolt
   	Connector

2. Disconnect the connector.
3. Remove the bolt and wire harness clamp bracket.
4. Disengage the clamp to remove the wire harness clamp bracket.

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5. Disconnect the grommet.

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   *a

   Grommet

1. Using a chisel and a hammer, lift the rear differential breather plug slightly.

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   NOTE:

   Do not damage the contact surface.

2. Using a screwdriver, remove the rear differential breather plug.

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   Using an 8 mm hexagon socket wrench, remove the rear differential carrier cover plug.

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   Using a 10 mm hexagon socket wrench, remove the rear differential filler plug and gasket.

1. Remove the 4 bolts.

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2. Using a brass bar and a hammer, lightly tap the electro magnetic control coupling sub-assembly to remove it from the rear differential carrier assembly.
   NOTE:

   • Set the brass bar on the ribbed part of the electro magnetic control coupling sub-assembly.
   • Do not damage the contact surface.

   HINT: 

   Temporarily install 2 bolts by approximately 5 or 6 threads to prevent the electro magnetic control coupling sub-assembly from falling.

3. Disconnect the connector.

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4. Remove the O-ring.

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   *a	Vertical Runout
   *b	Lateral Runout
   *c	45.5 mm (1.79 in.)

   Using a dial indicator, measure the runout of the electro magnetic control coupling sub-assembly vertical runout and lateral runout.

   Maximum Runout

   Item	Specified Condition
   Vertical runout	0.070 mm (0.00276 in.)
   Lateral runout	0.060 mm (0.00236 in.)

   NOTE:

   Measure the runout of the electro magnetic control coupling sub-assembly horizontally at a position 45.5 mm (1.79 in.) away from the electro magnetic control coupling sub-assembly.

   If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

1. Install 2 service nuts to the stud bolt.

   Recommended Service Nut

   Thread Diameter 

   10 mm (0.394 in.)

   Thread Pitch 

   1.0 mm (0.0394 in.)

2. Turn the lower nut and remove the other 3 stud bolts in the same way.

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   *a	Upper Nut
   *b	Lower Nut
   *c	Turn
   *d	Hold

   NOTE:

   Prevent foreign matter from entering the electro magnetic control coupling sub-assembly.

   HINT: 

   Lock the lower nut using the upper nut.

   If the threads of the electro magnetic control coupling sub-assembly are damaged while removing the stud bolt, replace the electro magnetic control coupling sub-assembly with a new one.

1. Using a screwdriver, partially separate the rear differential dust deflector.

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   *a	Protective Tape

   NOTE:

   • Separate the rear differential dust deflector to the extent the claws of SST can be inserted.
   • Do not damage the end surface of the electro magnetic control coupling sub-assembly.

   HINT: 

   Tape the screwdriver tip before use.

   If the end surface of the electro magnetic control coupling sub-assembly is damaged while removing the rear differential dust deflector, replace the electro magnetic control coupling sub-assembly with a new one.

2. Using SST, remove the rear differential dust deflector as shown in the illustration.
   • SST: 09950-40011 
     1. 09951-04020
     2. 09952-04010
     3. 09953-04030
     4. 09954-04010
     5. 09955-04061
     6. 09957-04010
     7. 09958-04011

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   *a	Turn
   *b	Hold

   NOTE:

   Before using the SST center bolt (09953-04030), apply grease to its threads and tip.

See step  7 [12/2019 - 10/2022], or see step  7 [10/2022 - 11/2023], or see step  7 [11/2023 - ]

1. Remove the transmission coupling spacer and conical spring washer from the rear differential carrier assembly.

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   *1	Transmission Coupling Spacer
   *2	Conical Spring Washer

See step  8 [12/2019 - 10/2022], or see step  8 [10/2022 - 11/2023], or see step  8 [11/2023 - ]

1. Using SST, remove the rear drive shaft oil seal LH from the rear differential carrier assembly.
   • SST: 09308-00010 

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   *1	Rear Drive Shaft Oil Seal LH

   NOTE:

   Do not damage the rear differential carrier assembly.

HINT: 

Use the same procedure as for the LH side.

1. Using a brass bar and a hammer, remove the rear differential dust deflector from the rear differential carrier assembly.

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HINT: 

Use the same procedure as for the LH side.