DIFFERENTIAL CASE DISASSEMBLY

PROCEDURE


  1. INSPECT FRONT DIFFERENTIAL CASE

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  2. REMOVE FRONT DIFFERENTIAL RING GEAR


    1. B002AHXC03
      *a Matchmark

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

    2. B002AE1

      Remove the 12 bolts from the front differential ring gear.

    3. B002A1A

      Using a plastic-faced 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. B0029WU

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

      Note

      Before removing the front differential pinion shaft straight pin, unstake it with a pin punch.

  4. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. B0029DG

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

  5. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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  6. REMOVE FRONT DIFFERENTIAL SIDE GEAR


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

      B0029B1C04
      *a Turn *b Hold
      SST
      09528-52010   ( 09528-05010, 09953-05010 )

      Note

      Do not overtighten SST, as doing so will damage the 2 front differential side gears, 2 conical spring washers, 2 front No. 1 differential side gear thrust washers and front differential case.

      Tech Tips


      • Tighten SST until there is 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. B0029SHC03
      *a Turn

      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 pinion and front differential pinion thrust washer.

    3. B0029FFC04
      *1 Front Differential Side Gear
      *2 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 conical spring washers from the front differential case.

      Note

      Do not drop the front differential side gear, front No. 1 differential side gear thrust washer or conical spring washer.