FRONT DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY


  1. FIX FRONT DIFFERENTIAL CARRIER ASSEMBLY TO OVERHAUL STAND


    1. A01GXYS

      Set the front differential carrier assembly to an overhaul stand as shown in the illustration.

  2. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. A01GYE8

      Connect a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the differential ring gear at a right angle.

    2. A01GWHME02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, turn the differential case clockwise and counterclockwise and measure the differential ring gear backlash while holding the companion flange with your hand.

      SST
      09564-32011
      Standard backlash
      0.15 to 0.23 mm (0.00591 to 0.00905 in.)

      Tech Tips


      • Measure at 3 or more areas around the circumference of the differential ring gear.

      • For reassembly purposes, record the result before disassembly.


      • If the backlash is not within the specified range, adjust the differential ring gear backlash or repair as necessary.

  3. INSPECT RUNOUT OF FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY


    1. A01H16AE04
      Text in Illustration
      *a 37 mm (1.46 in.)
      *b Vertical Runout
      *c Lateral Runout

      Wipe the inside surface of the companion flange with a cloth or equivalent and remove dirt and foreign matter.

    2. Perform the vertical runout inspection.


      1. Connect a lever probe to a dial indicator and set the probe at a right angle to the inner surface of the companion flange.

      2. Measure the vertical runout of the companion flange.

        Maximum runout
        0.12 mm (0.00472 in.)

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

        Tech Tips

        For reassembly purposes, record the result before disassembly.

    3. Perform the lateral runout inspection.


      1. Set a dial indicator at a right angle to the surface of the companion flange as shown in the illustration.

      2. Measure the lateral runout of the companion flange.

        Maximum runout
        0.08 mm (0.00315 in.)

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

        Tech Tips

        For reassembly purposes, record the result before disassembly.

  4. REMOVE FRONT DIFFERENTIAL BREATHER PLUG


    1. A01GY1F

      Remove the front differential breather plug from the differential carrier.

  5. REMOVE FRONT DIFFERENTIAL CASE OIL SEAL


    1. A01H1URE01

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

      SST
      09308-00010
    2. A01GYIQE01

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

      SST
      09308-00010
  6. REMOVE FRONT DIFFERENTIAL CARRIER RETAINER SUB-ASSEMBLY


    1. A01GZFC

      Loosen the 11 bolts.

    2. A01GXYS

      Remove the front differential carrier assembly from the overhaul attachment.

    3. A01H0K2

      Remove the 11 bolts.

    4. A01GWV0E01

      Insert the blade of an oil pan seal cutter between the differential carrier and front differential carrier retainer sub-assembly. Cut through the applied seal packing.

      Note

      Do not damage the installation surface of the differential carrier.

    5. Using a brass bar and hammer, lightly tap the front differential carrier retainer sub-assembly to remove it from the differential carrier.

      A01GYZC
  7. REMOVE NO. 1 FRONT DIFFERENTIAL CASE SUB-ASSEMBLY WITH RING GEAR


    1. A01GY8Z

      Remove the No. 1 differential case assembly with ring gear from the differential carrier.

      Note

      Do not damage the 2 front differential case bearings and differential ring gear.

  8. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01GX7T

      Uniformly apply a light coat of Prussian blue on both sides of 4 teeth on the differential ring gear.

    2. A01GY8Z

      Install the No. 1 front differential case sub-assembly with ring gear to the differential carrier.

    3. A01H0K2

      Install the front differential carrier retainer sub-assembly with the 11 bolts.

      Torque:
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }
    4. A01H0ZO

      Rotate the companion flange several times in the forward and backward rotation directions.

    5. A01H0K2

      Remove the 11 bolts and front differential carrier retainer sub-assembly.

    6. Remove the No. 1 front differential case sub-assembly with ring gear from the differential carrier.

    7. Inspect the tooth contact pattern.

      Tech Tips

      For reassembly purposes, record the result before disassembly.

      A01GY1OE01
      Text in Illustration
      *a Proper Contact *b Heel Contact
      *c Face Contact *d Select an adjusting washer that will shift the drive pinion closer to the ring gear (*b, *c)
      *e Toe Contact *f Flank Contact
      *g Select an adjusting washer that will shift the drive pinion away from to the ring gear (*e, *f) - -
  9. FIX DIFFERENTIAL CARRIER


    1. A01GYCA

      Fix the differential carrier to the overhaul stand.

  10. REMOVE FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A01H1VS

      Remove the 2 bolts and front differential breather plug oil deflector.

  11. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT


    1. A01GW4EE01

      Using SST and a hammer, unstake the staked part of the front drive pinion companion flange front nut.

      SST
      09930-00010

      Note


      • Be sure to use SST with the tapered surface facing the shaft.

      • Do not grind the tip of SST with a grinder etc.

      • Completely loosen the staked part of the nut when removing it.

      • Do not damage the threads of the drive pinion.

    2. A01GWIIE02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the flange, remove the front drive pinion companion flange front nut.

      SST
      09213-58013
      09229-55010
      09330-00021

      Note

      Perform the removal while supporting the overhaul attachment.

  12. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY


    1. A01GXONE02
      Text in Illustration
      *a Center Bolt
      *b Turn
      *c Hold

      Using SST, remove the front drive pinion companion flange front sub-assembly from the differential carrier.

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

      Tech Tips

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

  13. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR


    1. A01H0FME01

      Using SST and a press, press out the front differential dust deflector from the front drive pinion companion flange front sub-assembly.

      SST
      09950-00020
      09950-60010   ( 09951-00430 )
      09950-70010   ( 09951-07100 )

      Note


      • Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the front differential dust deflector.

      • Do not drop the front drive pinion companion flange front sub-assembly.

  14. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL


    1. A01H0T8E01

      Using a SST, remove the front differential carrier oil seal from the differential carrier.

      SST
      09308-00010
  15. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01GX6D

      Remove the front differential drive pinion oil slinger from the differential carrier.

  16. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING INNER RACE


    1. A01GZVX

      Remove the differential carrier together with the overhaul attachment from the engine stand.

    2. A01GXY7

      Set the differential carrier to an overhaul stand, etc. as shown in the illustration.

    3. A01GWHUE03
      Text in Illustration
      *1 Differential Drive Pinion
      *2 Front Drive Pinion Rear Tapered Roller Bearing Inner Race

      Using a press, press out the differential drive pinion.

      Note

      Do not drop the differential drive pinion.

    4. A01GZ99

      Remove the front drive pinion rear tapered roller bearing inner race from the differential carrier.

    5. A01GYNK

      Install the differential carrier to the overhaul attachment as it was installed previously.

    6. A01GX8K

      Install the differential carrier together with overhaul attachment to the engine stand.

  17. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01GZU0

      Remove the front differential drive pinion bearing spacer from the differential drive pinion.

  18. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING INNER RACE


    1. A01H0JCE01
      Text in Illustration
      *a Nut

      Using SST and a press, remove the front drive pinion front tapered roller bearing inner race from the differential drive pinion.

      SST
      09950-00020

      Note

      Do not drop the differential drive pinion.

      Tech Tips

      Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the front drive pinion front tapered roller bearing inner race.

      If either the differential drive pinion or the differential ring gear is damaged, replace both as a set.

  19. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING OUTER RACE


    1. A01GZPOE02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the front drive pinion rear tapered roller bearing outer race from the differential carrier.

      SST
      09387-00041   ( 09387-02020 )
  20. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING OUTER RACE


    1. A01H088E02
      Text in Illustration
      *1 Front Drive Pinion Spacer Adjust Shim

      Using SST and a hammer, tap out the front drive pinion front tapered roller bearing outer race and front drive pinion spacer adjust shim from the differential carrier.

      SST
      09950-70010   ( 09951-07150 )
      09950-60010   ( 09951-00610, 09951-00650, 09952-06010 )

      Tech Tips

      For reassembly purposes, measure the thickness of the front drive pinion spacer adjust shim, and record the result.

  21. REMOVE FRONT DIFFERENTIAL CASE BEARING LH


    1. A01H0HKE03
      Text in Illustration
      *1 Differential Case Washer
      *2 Front Differential Case Bearing LH (Outer Race)

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

      SST
      09950-60010   ( 09951-00510, 09952-06010 )
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07100 )
  22. REMOVE FRONT DIFFERENTIAL CASE BEARING RH


    1. A01GXZTE02
      Text in Illustration
      *1 Differential Case Washer
      *2 Front Differential Case Bearing RH (Outer Race)

      Using SST and a press, press out the front differential case bearing RH (outer race) and differential case washer from the front differential carrier retainer sub-assembly.

      SST
      09950-60010   ( 09951-00520 )
      09950-70010   ( 09951-07100 )
  23. REMOVE FRONT DIFFERENTIAL CASE BEARING LH


    1. A01H110E02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the front differential case bearing LH (inner race) from the No. 1 front differential case sub-assembly with ring gear.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00460 )

      Note

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

  24. REMOVE FRONT DIFFERENTIAL CASE BEARING RH


    1. A01GY48E02
      Text in Illustration
      *a Turn
      *b Hold
      *c Roller Cage
      *d Roller

      Using SST, remove the roller cage and bearing rollers.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04011, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00510 )

      Note

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

    2. A01H1HRE02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the race from the No. 1 front differential case sub-assembly with ring gear.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04011, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00510 )

      Note

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

  25. REMOVE DIFFERENTIAL RING GEAR


    1. A01H0O5E02
      Text in Illustration
      *a Aluminum Plate

      Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A01GZT9E02
      Text in Illustration
      *a Matchmark

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

    3. A01GWKV

      Remove the 10 differential ring gear set bolts.

    4. Remove the differential case from the vise.

    5. A01H0RD

      Using a plastic-faced hammer, tap on the differential ring gear to separate it from the No. 1 front differential case sub-assembly.

      Tech Tips

      Place a cloth on the tooth side of the differential ring gear to prevent damage.