DIFFERENTIAL CASE DISASSEMBLY

PROCEDURE

1. REMOVE FRONT DRIVE SHAFT OIL SEAL RH

   
   

   1. for Outside:

      
      

      1. 

         Using SST, remove the front drive shaft oil seal RH from the transaxle housing.

         SST

         09308-00010

   2. 

      for Inside:

      
      

      1. Using SST, remove the front drive shaft oil seal RH from the front differential case.

         SST

         09308-00010

2. REMOVE FRONT DRIVE SHAFT OIL SEAL LH

   
   

   1. 

      Using SST, remove the front drive shaft oil seal LH from the transaxle case sub-assembly.

      SST

      09308-00010

3. INSPECT FRONT DIFFERENTIAL CASE

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4. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

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5. REMOVE FRONT DIFFERENTIAL RING GEAR

   
   

   1. 

      *a

      Matchmark

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

   2. 

      Remove the 12 bolts from the front differential ring gear.

   3. 

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

6. 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. 

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

7. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT

   
   

   1. 

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

8. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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9. REMOVE FRONT DIFFERENTIAL SIDE GEAR

   
   

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

      

      *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 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. 

      *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. 

      *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 gear, front No. 1 differential side gear thrust washer or conical spring.

10. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    
    

    1. 

       *a	Turn
       *b	Hold

       Using SST, remove the front differential case front tapered roller bearing (inner race) from the front differential case.

       SST

       09950-00020

       09950-00030

       09950-40011   ( 09957-04010 )

       09950-60010   ( 09951-00480 )

    2. 

       Using SST, remove the front differential case front tapered roller bearing (outer race) and shim from the transaxle housing.

       SST

       09308-00010

11. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    
    

    1. 

       *a	Turn
       *b	Hold

       Using SST, remove the front differential case rear tapered roller bearing (inner race) from the front differential case.

       SST

       09950-00020

       09950-00030

       09950-40011   ( 09957-04010 )

       09950-60010   ( 09951-00480 )

    2. 

       Using SST, remove the front differential case rear tapered roller bearing (outer race) from the transaxle case sub-assembly.

       SST

       09308-00010