DIFFERENTIAL CASE DISASSEMBLY


  1. INSPECT FRONT DIFFERENTIAL CASE


    1. B000KCJE01

      Using SST, rotate the front differential side gear as shown in the illustration.

      SST
      09528-52010   ( 09528-05030 )
      Standard
      The front differential side gear does not lock when rotated in either direction.

      • If the front differential side gear locks, perform all of the following inspections.

      • If the front differential side gear still locks after replacing the malfunctioning parts, replace the front differential case.

      • Replace any parts that do not meet the specifications.

  2. REMOVE FRONT DIFFERENTIAL RING GEAR


    1. B000JBFE01
      Text in Illustration
      *a Matchmark

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

    2. B000NHX

      Remove the 12 bolts.

    3. B000LAL

      Using a plastic hammer, tap on the front differential ring gear to remove it from the front differential case.

  3. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


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

      Note

      Do not overtighten the vise.

    2. B000GXQ

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

  4. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. B000MN9

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

  5. INSPECT FRONT DIFFERENTIAL PINION BACKLASH


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

      B000JD2E01
      Text in Illustration
      *a Turn *b Hold
      SST
      09528-52010   ( 09528-05010, 09953-05010 )
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Secure the front differential case with front differential ring gear in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. B000JX0E01
      Text in Illustration
      *1 Front No. 1 Differential Pinion Shaft

      Install the front No. 1 differential pinion shaft to the front differential pinion as shown in the illustration.

    4. Using a dial indicator, measure the front differential pinion backlash.

      Standard Backlash
      0.20 mm (0.00787 in.) or less

      If the backlash is not as specified, replace the front No. 1 differential side gear thrust washers with washers of a different thickness. Use the table below to select front No. 1 differential side gear thrust washers which will ensure that the backlash is within the specification.

      Tech Tips

      Select front No. 1 differential side gear thrust washers of the same thickness for both the right and left side.

      Front No. 1 Differential Side Gear Thrust Washer Thickness:
      Part No. Thickness (mm (in.))
      41361-73050 0.90 (0.0354)
      41361-73010 1.00 (0.0394)
      41361-73020 1.10 (0.0433)
      41361-73030 1.20 (0.0472)

  6. REMOVE FRONT DIFFERENTIAL SIDE GEAR


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

      B000IOHE01
      Text in Illustration
      *a Turn *b Hold
      SST
      09528-52010   ( 09528-05010, 09953-05010 )

      Note

      Do not overtighten SST, as doing so will damage the front differential side gears, conical springs, front No. 1 differential side gear thrust washers and front differential case.

      Tech Tips


      • Tighten SST to create the necessary clearance to remove the front differential pinions.

      • When removing the front differential pinions, do not overtighten SST, as it is necessary to rotate the front differential side gears.

    2. B000LWKE01
      Text in Illustration
      *a Turn

      Install SST as shown in the illustration and rotate the front differential side gear to 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. B000IDZE01
      Text in Illustration
      *1 Front Differential Side Gear
      *2 Conical Spring
      *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 conical springs from the front differential case.

      Note

      Do not drop the front differential side gears, front No. 1 differential side gear thrust washers or conical springs.