FRONT DIFFERENTIAL CARRIER OIL SEAL(for AWD) REPLACEMENT

PROCEDURE

1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

2. DRAIN DIFFERENTIAL OIL

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3. REMOVE ENGINE ASSEMBLY

   
   

   1. Remove the engine assembly Click here.

4. INSTALL ENGINE ON TO ENGINE STAND

   
   

   1. Install the engine onto an engine stand with the bolts.

   2. Remove the 2 bolts and 2 engine hangers.

5. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY

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6. FIX FRONT DIFFERENTIAL CARRIER ASSEMBLY TO OVERHAUL STAND

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7. REMOVE FRONT DIFFERENTIAL CARRIER RETAINER SUB-ASSEMBLY

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8. REMOVE NO. 1 FRONT DIFFERENTIAL CASE SUB-ASSEMBLY

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9. FIX DIFFERENTIAL CARRIER

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10. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT

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11. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY WITH DEFLECTOR

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12. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL

    
    

    1. 

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

       SST

       09308-00010

13. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

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14. REMOVE DIFFERENTIAL DRIVE PINION WITH BEARING INNER RACE

    
    

    1. 

       Text in Illustration

       *a	Overhaul Attachment

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

    2. 

       Install the differential carrier to the attachment as shown in the illustration.

    3. 

       Text in Illustration

       *1	Differential Drive Pinion
       *2	Bearing Inner Race

       Using a press, remove the differential drive pinion with bearing inner race from the differential carrier.

       Note

       Do not drop the differential drive pinion or bearing inner race.

15. REPLACE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

    
    

    1. 

       Replace the front differential drive pinion bearing spacer with a new one and install it to the differential drive pinion with bearing inner race.

16. INSTALL DIFFERENTIAL DRIVE PINION WITH BEARING INNER RACE

    
    
    1. 

       Text in Illustration

       *a	Center Bolt
       *b	Turn
       *c	Hold

       Using SST and the companion flange, install the differential drive pinion with bearing inner race.

       SST

       09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060 )

       Tech Tips

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

    2. Using SST, remove the companion flange.

17. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

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18. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL

    
    
    1. 

       Text in Illustration

       *1	Front Differential Carrier Oil Seal

       Using SST and a hammer, tap in a new front differential carrier oil seal.

       SST

       09309-36010

       09502-24010

       Standard depth
       6.2 to 7.2 mm (0.244 to 0.283 in.)

       Note

       
       

       • Using a vernier caliper, measure the depth of the front differential carrier oil seal.

       • Measure at 3 or more areas around the circumference of the front differential carrier oil seal

       • Make sure the difference between the maximum and minimum measured values is less than 0.75 mm (0.0295 in.), as a greater difference may lead to oil leaks.

       • Tap the front differential carrier oil seal uniformly so that the front differential carrier oil seal is straight.

       • Do not excessively tap the front differential carrier oil seal.

       Tech Tips

       First, uniformly tap in the front differential carrier oil seal until it is flush with the edge of the carrier, and then tap it little by little until the depth is within the standard range.

19. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY WITH DEFLECTOR

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20. INSPECT DRIVE PINION PRELOAD

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21. INSTALL NO. 1 FRONT DIFFERENTIAL CASE SUB-ASSEMBLY

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22. INSTALL FRONT DIFFERENTIAL CARRIER RETAINER SUB-ASSEMBLY

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23. INSPECT TOTAL PRELOAD

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24. STAKE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT

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25. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY FROM OVERHAUL STAND

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26. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY

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27. INSTALL ENGINE TO VEHICLE

    
    

    1. Remove the engine from the engine stand and then install it to the vehicle Click here.

28. ADD DIFFERENTIAL OIL

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