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FRONT DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY

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PROCEDURE


  1. Click here

    REMOVE DIFFERENTIAL EXTENSION FLANGE TUBE


    1. A01X7IE

      Remove the 4 bolts.

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

  2. Click here

    REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01X84XE02

      Using SST, tap out the oil seal.

      09308-00010
  3. Click here

    REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT


    1. A01X071E03

      Using SST and a hammer, unstake the nut.

      09930-00010
    2. A01X9B9E02

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

      09330-00021 09330-00030
  4. Click here

    REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01X5NCE01

      Using SST, remove the companion flange from the differential carrier.

      09950-30012 09951-03010 09953-03010 09954-03010 09955-03030 09956-03020
  5. Click here

    REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL


    1. A01XC4GE02

      Using SST, remove the oil seal.

      09308-10010
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    REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

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    REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER


    1. A01XA60E01

      Remove the bolts labeled B and front differential front support assembly LH.

    2. Remove the bolts labeled A.

    3. Using a plastic-faced hammer, tap out the bearing retainer.

  8. Click here

    REMOVE FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY


    1. Remove the differential case from the differential carrier.

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    REMOVE DIFFERENTIAL DRIVE PINION


    1. A01X2A5E05
      Table 1.
      *1 Block

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

    2. Using a press, press out the drive pinion.

      Note:

      Do not drop the drive pinion.

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    REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING


    1. Remove the bearing (inner race) from the differential carrier.

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    REMOVE FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A01X0BN

      Remove the 2 bolts and oil deflector.

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    REMOVE FRONT DIFFERENTIAL UNION


    1. A01XAYR

      Remove the front differential union from the differential carrier.

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    REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01X9EGE01

      Using SST and a press, press out the bearing (inner race) from the drive pinion.

      09950-00020

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

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    REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01X47H

      Using a brass bar and hammer, tap out the bearing (outer race) and washer.

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    REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING


    1. A01X8HRE03

      Using SST and a hammer, tap out the bearing (outer race) from the differential carrier.

      09950-70010 09951-07100
      09950-60010 09951-00450
      09950-60020 09951-00710 09952-06010
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    REMOVE FRONT DIFFERENTIAL CASE BEARING

    Tip:

    • Measure the plate washer and note its thickness.

    • Tag the bearing outer races to show the location for reassembly.


    1. A01XALRE02
      Table 2.
      *1 Plate Washer

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

      09950-60020 09951-00680
      09950-70010 09951-07150
    2. A01X6XTE05
      Table 3.
      *1 Plate Washer

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

      09950-60020 09951-00680
      09950-70010 09951-07150
  17. Click here

    REMOVE DIFFERENTIAL RING GEAR


    1. A01X22PE03
      Table 4.
      *1 Matchmark

      Place matchmarks on the ring gear and differential case.

    2. Remove the 12 bolts.

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

  18. Click here

    REMOVE FRONT DIFFERENTIAL CASE BEARING


    1. A01X0W4E01

      Using SST, remove the 2 bearings (inner race).

      09950-60010 09951-00390
      09950-40011 09951-04020 09952-04010 09953-04030 09954-04010 09955-04061 09957-04010 09958-04011
      Tip:

      Fix the claws of SST into the notch in the differential case assembly.

  19. Click here

    DISASSEMBLE DIFFERENTIAL CASE


    1. A01WZZAE05
      Table 5.
      *1 Straight Pin

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

    2. Remove these parts from the differential case assembly.


      1. 2 differential side gears

      2. 2 differential side gear thrust washers

      3. Differential pinion shaft

      4. 2 differential pinion gears

      5. 2 differential pinion gear thrust washers

  20. Click here

    INSPECT DIFFERENTIAL GEAR KIT


    1. Check that there is no damage to the pinion gears and side gears.

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

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    INSPECT FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY


    1. Check that the differential case is not damaged.

      If the differential case is damaged, replace it.

  22. Click here

    REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01X783E09

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

      09308-00010
  23. Click here

    REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH


    1. A01X6OF

      Using a snap ring pliers, remove the snap ring.

    2. A01X6AF

      Using a plastic-faced hammer, tap out the side gear shaft.

  24. Click here

    REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING


    1. A01X1CY

      Using a snap ring expander, remove the snap ring.

    2. A01X6XZE03

      Using SST and a press, press out the bearing.

      09950-00020
      09950-70010 09951-07100
      09950-60010 09951-00450
      Note:

      Do not damage the bearing.

  25. Click here

    REMOVE FRONT DIFFERENTIAL CARRIER STRAIGHT PIN


    1. A01X3ZV

      Remove the straight pins from the bearing retainer.

  26. Click here

    REMOVE FRONT DIFFERENTIAL TUBE STRAIGHT PIN


    1. A01X70Z

      Remove the straight pins from the bearing retainer.