FRONT DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY

PROCEDURE


  1. REMOVE DIFFERENTIAL EXTENSION FLANGE TUBE


    1. A01WT8Y

      Remove the 4 bolts.

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

  2. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01WVYAE02

      Using SST, tap out the oil seal.

      SST
      09308-00010

  3. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT


    1. A01WSFGE03

      Using SST and a hammer, unstake the nut.

      SST
      09930-00010
    2. A01WRXKE02

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

      SST
      09330-00021   ( 09330-00030 )

  4. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01WVB5E05
      Text in Illustration
      *a Turn
      *b Hold

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

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

  5. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL


    1. A01WTQGE02

      Using SST, remove the oil seal.

      SST
      09308-10010

  6. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

  7. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER


    1. A01WP9QE01

      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. REMOVE FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY


    1. Remove the differential case from the differential carrier.

  9. REMOVE DIFFERENTIAL DRIVE PINION


    1. A01WVA4E03
      Text in Illustration
      *a 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.

  10. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING


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

  11. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

  12. REMOVE FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A01WPKP

      Remove the 2 bolts and oil deflector.

  13. REMOVE FRONT DIFFERENTIAL UNION


    1. A01WUW8

      Remove the front differential union from the differential carrier.

  14. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01WRXSE08

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

      SST
      09950-00020

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

  15. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01WUKF

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

  16. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING


    1. A01WRQLE03

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

      SST
      09950-70010   ( 09951-07100 )
      09950-60010   ( 09951-00450 )
      09950-60020   ( 09951-00710, 09952-06010 )

  17. REMOVE FRONT DIFFERENTIAL CASE BEARING

    Tech Tips


    • Measure the plate washer and note its thickness.

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


    1. A01WS12E04
      Text in Illustration
      *1 Plate Washer

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

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07150 )
    2. A01WQNVE04
      Text in Illustration
      *1 Plate Washer

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

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

  18. REMOVE DIFFERENTIAL RING GEAR


    1. A01WTM4E01
      Text in Illustration
      *a 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.

  19. REMOVE FRONT DIFFERENTIAL CASE BEARING


    1. A01WTX0E01

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

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

      Tech Tips

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

  20. DISASSEMBLE DIFFERENTIAL CASE


    1. A01WV2OE03
      Text in Illustration
      *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

  21. 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.

  22. 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.

  23. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A01WSKPE05

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

      SST
      09308-00010

  24. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH


    1. A01WWK5

      Using a snap ring expander, remove the snap ring.

    2. A01WUEU

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

  25. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING


    1. A01WPE3

      Using a snap ring expander, remove the snap ring.

    2. A01WSAZE02

      Using SST and a press, press out the bearing.

      SST
      09950-00020
      09950-70010   ( 09951-07100 )
      09950-60010   ( 09951-00450 )

      Note

      Do not damage the bearing.

  26. REMOVE FRONT DIFFERENTIAL CARRIER STRAIGHT PIN


    1. A01WRG9

      Remove the straight pins from the bearing retainer.

  27. REMOVE FRONT DIFFERENTIAL TUBE STRAIGHT PIN


    1. A01WQ1X

      Remove the straight pins from the bearing retainer.