DIFFERENTIAL CASE DISASSEMBLY

PROCEDURE


  1. INSPECT FRONT DIFFERENTIAL CASE (w/ Pre-torque Mechanism)

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  2. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT (w/ Pre-torque Mechanism)

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  3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH (w/o Pre-torque Mechanism)

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  4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. Secure the front differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A01VLJL

      Using a 5 mm pin punch and a hammer, remove the front differential pinion shaft straight pin from the front differential case.

  5. INSPECT FRONT DIFFERENTIAL PINION BACKLASH (w/ Pre-torque Mechanism)

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  6. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A01VKWL

      Remove the front No. 1 differential pinion shaft from the front differential case.

  7. REMOVE FRONT DIFFERENTIAL SIDE GEAR (w/ Pre-torque Mechanism)


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

      A01VGWYE02
      Text in Illustration
      *a Turn *b Hold
      SST
      09528-52010   ( 09953-05010, 09528-05020 )

      Note

      Do not overtighten SST, as doing so will damage the front differential side gears, front conical spring washers, front No. 1 differential side gear thrust washers and front differential case.

      Tech Tips


      • Tighten SST until there is 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. A01VLYSE01
      Text in Illustration
      *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 differential case.

      SST
      09528-52010   ( 09528-05040 )

      Note

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

    3. A01VIX3E02
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Front Conical Spring Washer
      *3 Front No. 1 Differential Side Gear Thrust Washer

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

      Note

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

  8. REMOVE FRONT DIFFERENTIAL SIDE GEAR (w/o Pre-torque Mechanism)


    1. A01VJV2

      Remove the 2 front differential pinions, 2 front differential pinion thrust washers, 2 front No. 1 differential side gear thrust washers, and 2 front differential side gears from the front differential case.

      Tech Tips

      While rotating the front differential side gears, remove the 2 front differential pinions and 2 front differential pinion thrust washers.