FRONT DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY


  1. INSPECT DIFFERENTIAL RING GEAR BACKLASH

    A01DQDLE01

    1. Using SST and a dial indicator, measure the ring gear backlash.

      SST
      09564-32011
      Standard backlash
      0.11 to 0.21 mm (0.00433 to 0.00827 in.)

      If the backlash is not as specified, adjust the side bearing preload or perform repairs as necessary.

      Tech Tips

      Perform the measurement at 3 or more positions around the circumference of the ring gear.

  2. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    A01DOC6E16
    Text in Illustration
    *a Vertical Runout
    *b Lateral Runout

    1. Using a dial indicator, measure the runout of the companion flange vertically and laterally.

      Distance from center to runout measurement point
      30 mm (1.18 in.)
      Maximum Runout
      Item Specified Condition
      Vertical runout 0.15 mm (0.00591 in.)
      Lateral runout 0.15 mm (0.00591 in.)

      If the runout is more than the maximum, replace the companion flange.

  3. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY


    1. A01DNIR

      Using an E14 "TORX" socket wrench, remove the 4 bolts.

    2. Using a plastic-faced hammer, tap out the differential tube.

  4. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01DRMVE01

      Using SST, remove the 2 oil seals.

      SST
      09308-00010

  5. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT

    A01DU5GE01

    1. Using SST and a hammer, unstake the nut.

      SST
      09930-00010
    2. A01DQDUE05

      Using SST to hold the companion flange, remove the nut.

      SST
      09330-00021

  6. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    A01DTU0E06
    Text in Illustration
    *a Hold
    *b Turn

    1. Using SST, remove the companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020 )

      Note

      Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

  7. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR

    A01DS49E02

    1. Using SST and a press, press out the dust deflector.

      SST
      09950-00020
      09950-60010   ( 09951-00510 )
      09950-70010   ( 09951-07150 )

      Note

      Do not drop the companion flange.

  8. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL


    1. A01DOODE03

      Using SST, remove the oil seal from the differential carrier assembly.

      SST
      09308-10010

  9. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. Remove the oil slinger from the drive pinion.

  10. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (INNER)


    1. A01DPOOE03

      Using SST, remove the front tapered roller bearing (inner) from the drive pinion.

      SST
      09556-22010

  11. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (OUTER)


    1. A01DMGFE06

      Using SST, remove the front tapered roller bearing (outer).

      SST
      09308-00010

  12. REMOVE FRONT DIFFERENTIAL OIL STORAGE RING


    1. Using a screwdriver and hammer, tap out the oil storage ring.

  13. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

    A01DRSQ

    1. Remove the bearing spacer.

  14. REMOVE DIFFERENTIAL SIDE BEARING RETAINER


    1. Using a screwdriver, remove the union.

    2. Remove the 10 bolts and tap out the side bearing retainer with a plastic-faced hammer.

  15. REMOVE DIFFERENTIAL CASE ASSEMBLY

  16. REMOVE DIFFERENTIAL DRIVE PINION

  17. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (INNER)


    1. A01DNNGE02

      Using SST and a press, remove the rear tapered roller bearing (inner) and washer from the drive pinion.

      SST
      09950-00020

      Tech Tips

      If the drive gear or ring gear is damaged, replace them as a set.

      Note

      Do not drop the drive pinion.

  18. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER)


    1. A01DNLN

      Using a brass bar and hammer, remove the rear tapered roller bearing (outer).

  19. REMOVE FRONT DIFFERENTIAL CASE BEARING

    A01DMP7E01

    Tech Tips


    • Measure the thickness of the case washer.

    • Tag the bearing outer races so that they can be reinstalled in the correct locations.


    1. Using SST and a press, press out the case bearing (outer race) and case washer from the bearing retainer.

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07150 )

      If the bearing is damaged during removal, replace it.

    2. A01DLT7E01

      Using SST and a press, press out the case bearing (outer race) and plate washer from the differential carrier.

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07150 )

      If the bearing is damaged during removal, replace it.

  20. REMOVE DIFFERENTIAL RING GEAR

    A01DTDJE02

    1. Place matchmarks on the ring gear and differential case.

      Text in Illustration
      *a Matchmark

    2. Remove the 10 ring gear set bolts.

    3. A01DSLLE01

      Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.

  21. REMOVE FRONT DIFFERENTIAL CASE BEARING

    Tech Tips

    The differential case and case bearings should only be removed when replacement is necessary.


    1. A01DPQSE03
      Text in Illustration
      *a Notch

      Using SST, remove the 2 differential case bearings (inner) from the differential case.

      SST
      09950-60010   ( 09951-00390 )
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )

      Tech Tips

      Set the claws of SST into the notches in the differential case.

  22. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. A01DUO1E01

      Using a chisel and hammer, unstake the differential case.

    2. A01DTGHE01

      Using a 5 mm pin punch and hammer, tap out the straight pin.

    3. A01DR9AE01
      Text in Illustration
      *1 Differential Pinion Gear
      *2 Differential Pinion Gear Thrust Washer
      *3 Differential Pinion Shaft
      *4 Differential Side Gear
      *5 Differential Side Gear Thrust Washer

      Remove the parts shown in the illustration from the differential case.

  23. INSPECT DIFFERENTIAL GEAR KIT


    1. Check that the differential pinion and differential side gear are not damaged.

      If the differential pinion or differential side gear is damaged, replace the differential gear kit.

  24. INSPECT FRONT DIFFERENTIAL CASE


    1. Check that the differential case is not damaged.

      If the differential case is damaged, replace it.

  25. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01DOTFE01

      Using SST, tap out the oil seal from the differential tube.

      SST
      09308-00010

  26. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH


    1. A01DMTJ

      Using a snap ring expander, remove the snap ring.

    2. Remove the side gear shaft from the differential tube.

  27. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT BEARING RH


    1. A01DO8JE02

      Using a snap ring expander, remove the snap ring.

    2. Using SST, a brass bar and press, press out the bearing.

      SST
      09950-00020

      Note


      • Do not damage the bearing.

      • Do not drop the shaft.