DIFFERENTIAL CASE DISASSEMBLY

PROCEDURE

1. REMOVE FRONT DIFFERENTIAL CASE OIL SEAL

   1. 

      Using SST, remove the front differential case oil seal from the front differential case.

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2. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

   1. 

      *a	Turn
      *b	Hold

      Using SST, remove the front differential case front tapered roller bearing from the front differential case.

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3. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

   1. 

      *a	Turn
      *b	Hold

      Using SST, remove the front differential case rear tapered roller bearing from the front No. 1 differential case sub-assembly.

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4. REMOVE FRONT DIFFERENTIAL RING GEAR

   1. Mount the front differential ring gear in a vise between aluminum plates.

      Note:

      • Be careful not to damage the front differential ring gear.

      • Do not overtighten the vise.

   2. 

      *a

      Matchmark

      Put matchmarks on the front differential ring gear and front No. 1 differential case sub-assembly.

   3. 

      Remove the 16 bolts.

   4. Using a plastic-faced hammer, remove the front No. 1 differential case sub-assembly from the front differential ring gear.

5. INSPECT FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY

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6. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

   1. 

      Using a 5 mm pin punch and hammer, remove the front differential pinion shaft straight pin from the front No. 1 differential case sub-assembly.

7. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT

   1. 

      Remove the front No. 1 differential pinion shaft from the front No. 1 differential case sub-assembly.

8. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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9. REMOVE FRONT DIFFERENTIAL SIDE GEAR

   1. Set SST as shown in the illustration and tighten it.

      

      *a

      Turn

      *b

      Hold

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      Note:

      Do not overtighten SST, as doing so will damage the front differential side gear, conical spring, front No. 1 differential side gear thrust washer and front No. 1 differential case sub-assembly.

      Tip:

      • Tighten SST until there is a clearance between the front differential pinions and front differential side gears.

      • When removing the front differential pinions, do not overtighten SST, as it is necessary to rotate the front differential side gears.

   2. 

      *a

      Turn

      Install SST as shown in the illustration, rotate the front differential side gear, and then remove the 2 front differential pinions and 2 front differential pinion thrust washers from the front No. 1 differential case sub-assembly.

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      Note:

      Do not drop the front differential pinion and front differential pinion thrust washer.

   3. 

      *1	Front Differential Side Gear
      *2	Conical Spring
      *3	Front No. 1 Differential Side Gear Thrust Washer

      Remove SST from the front No. 1 differential case sub-assembly, and then remove the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs from the front No. 1 differential case sub-assembly.

      Note:

      Do not drop the front differential side gear, front No. 1 differential side gear thrust washer and conical spring.