DIFFERENTIAL CASE DISASSEMBLY

PROCEDURE


  1. REMOVE FRONT DIFFERENTIAL RING GEAR


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

      Note


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

      • Do not overtighten the vise.

    2. A00563JE03
      Text in Illustration
      *a Matchmark

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

    3. A005307

      Remove the 12 bolts.

    4. Using a plastic-faced hammer, remove the front differential ring gear from the front differential case.

  2. INSPECT FRONT DIFFERENTIAL CASE

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  3. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

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  4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A00595P

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

  5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A0057KD

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

  6. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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  7. REMOVE FRONT DIFFERENTIAL SIDE GEAR


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

      SST
      09528-52010   ( 09953-05010, 09528-05010 )
      A00564GE05
      Text in Illustration
      *a Turn *b Hold

      Note

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

      Tech Tips


      • 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. A0053BIE05

      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   ( 09528-05030 )

      Note

      Do not drop the front differential pinions and front differential pinion thrust washers.

    3. A0058EEE06
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Center Differential Side Gear 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 center differential side gear conical spring washers from the front differential case.

      Note

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