DIFFERENTIAL CASE DISASSEMBLY

PROCEDURE


  1. INSPECT FRONT DIFFERENTIAL CASE

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  2. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

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  3. REMOVE FRONT DIFFERENTIAL RING GEAR


    1. B006QXGC01
      *a Matchmark

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

    2. B006OY1

      Remove the 12 bolts.

    3. B006KR9

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

  4. 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. B006R4H

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

  5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. B006LLH

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

  6. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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  7. REMOVE FRONT DIFFERENTIAL SIDE GEAR


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

      B006NPAC01
      *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. B006OEBC01
      *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. B006QR9C01
      *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.