DIFFERENTIAL CASE DISASSEMBLY

PROCEDURE


  1. REMOVE FRONT DIFFERENTIAL RING GEAR


    1. Mount the front differential ring gear in a vise between aluminum plates.

      Note


      • Be careful not to damage the front differential ring gear.


      • Do not overtighten the vise.

    2. A01GCTFC06
      *a Matchmark

      Put matchmarks on the front differential ring gear and front differential case sub-assembly.

    3. A01GBDP

      Remove the 12 bolts.

    4. Using a plastic-faced hammer, remove the front differential ring gear from the front differential case sub-assembly.

  2. INSPECT FRONT DIFFERENTIAL CASE SUB-ASSEMBLY

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  3. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

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  4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. Mount the front differential case sub-assembly in a vise between aluminum plates.

      Note


      • Be careful not to damage the front differential case sub-assembly.


      • Do not overtighten the vise.

    2. A01GBAG

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

  5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A01GAF8

      Remove the front No. 1 differential pinion shaft from the front differential case sub-assembly.

  6. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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  7. REMOVE FRONT DIFFERENTIAL SIDE GEAR


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

      SST
      09528-52010   ( 09953-05010, 09528-05010 )
      A01GBZ0C03
      *a Turn *b Hold

      Note

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

      Tech Tips


      • Tighten SST until there is a 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. A01GAILC01
      *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 sub-assembly.

      SST
      09528-52010   ( 09528-05030 )

      Note

      Do not drop the front differential pinion or front differential pinion thrust washer.

    3. A01GC57C02
      *1 Front Differential Side Gear
      *2 Center Differential Side Gear Conical Spring Washer
      *3 Front No. 1 Differential Side Gear Thrust Washer

      Remove SST from the front differential case sub-assembly, and then remove the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 center differential side gear 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 and center differential side gear conical spring washer.