FRONT DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY

PROCEDURE


  1. INSPECT DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH


    1. B003LCPN04

      Using SST and a dial indicator, measure the differential ring gear backlash.

      SST
      09564-33010
      Standard Backlash
      0.11 to 0.21 mm (0.00433 to 0.00826 in.)

      • If the backlash is not as specified, adjust the side bearing preload or perform repairs as necessary.

        Tech Tips

        Perform the measurement at 3 or more positions around the circumference of the differential ring gear.

  2. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. B003LE1C05
      *a 30 mm (1.18 in.)

      Using a dial indicator, measure the runout of the front drive pinion companion flange vertically and laterally.

      Maximum Runout
      Item Specified Condition
      Vertical runout 0.10 mm (0.00394 in.)
      Lateral runout 0.10 mm (0.00394 in.)

      • If the runout is more than the maximum, replace the front drive pinion companion flange.

  3. REMOVE OIL TEMPERATURE SENSOR


    1. B003QN2

      Remove the oil temperature sensor from the front differential carrier assembly.

  4. REMOVE DIFFERENTIAL MOTOR ACTUATOR ASSEMBLY (w/ A.D.D.)


    1. B003Q70

      Remove the 4 bolts.

    2. B003NKV

      Using a hammer, pry out the differential motor actuator assembly from the front differential tube assembly.

  5. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY


    1. B003KXP

      Using an E14 ''TORX'' socket wrench, remove the 4 bolts.

    2. Using a plastic-faced hammer, tap out the front differential tube assembly.

  6. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL LH


    1. B003REWN01

      Using SST, tap out the differential side gear shaft oil seal LH.

      SST
      09308-00010

  7. REMOVE DIFFERENTIAL CLUTCH SLEEVE (w/ A.D.D.)


    1. Remove the differential clutch sleeve.

  8. REMOVE DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY (w/ A.D.D.)


    1. Remove the side gear intermediate shaft hole snap ring from the differential side gear inter shaft sub-assembly.

    2. B003KVUC02
      *a Turn
      *b Hold

      Using SST, remove the differential side gear inter shaft sub-assembly.

      SST
      09350-20015   ( 09369-20040 )
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011 )

  9. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR (w/ A.D.D.)


    1. B003QRHC04
      *a Protective Tape

      Using a screwdriver, pry out the front differential side bearing retainer deflector.

      Tech Tips

      Tape the screwdriver tip before use.

  10. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT

    Click here

  11. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY WITH DUST DEFLECTOR

    Click here

  12. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL

    Click here

  13. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

    Click here

  14. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B003KR2N01

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

      SST
      09556-22010

  15. REMOVE DIFFERENTIAL SIDE BEARING RETAINER


    1. Remove the 10 bolts and tap out the differential side bearing retainer with a plastic-faced hammer.

  16. REMOVE DIFFERENTIAL CASE ASSEMBLY

  17. REMOVE DIFFERENTIAL DRIVE PINION

  18. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

    Click here

  19. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B003NLJN01

      Using SST and a press, press out the front drive pinion front tapered roller bearing (inner) and drive pinion plate washer from the differential drive pinion.

      SST
      09950-00020

      Note

      Do not drop the differential drive pinion.

      Tech Tips

      If the differential drive pinion or differential ring gear is damaged, replace them as a set.

  20. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B003J4XC02
      *a Turn
      *b Hold

      Using SST, remove the front drive pinion rear tapered roller bearing (outer).

      SST
      09502-12010
      09612-65014   ( 09612-01020, 09612-01050 )

  21. REMOVE FRONT DIFFERENTIAL OIL STORAGE RING


    1. Using a brass bar and hammer, tap out the front differential oil storage ring.

  22. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B003JO5

      Using a brass bar and hammer, tap out the front drive pinion front tapered roller bearing (outer).

  23. REMOVE FRONT DIFFERENTIAL CASE BEARING

    Tech Tips


    • Measure the thickness of the case washer.

    • Tag the bearing outer races so that they can be reinstalled in the correct locations.


    1. B003QYON02

      Using SST and a press, press out the front differential case bearing (outer) and plate washer from the differential side bearing retainer.

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07150 )

      • If the bearing is damaged during removal, replace it.

    2. B003QGBN02

      Using SST and a press, press out the front differential case bearing (outer) and plate washer from the differential carrier.

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07150 )

      • If the bearing is damaged during removal, replace it.

  24. REMOVE DIFFERENTIAL RING GEAR


    1. B003P3TC01
      *a Matchmark

      Place matchmarks on the differential ring gear and differential case.

    2. Remove the 10 differential ring gear set bolts.

    3. B003NCU

      Using a plastic-faced hammer, tap on the differential ring gear to separate it from the differential case assembly.

  25. REMOVE FRONT DIFFERENTIAL CASE BEARING

    Tech Tips

    The differential case and case bearings should only be removed when replacement is necessary.


    1. B003M2OC02
      *a Notch
      *b Turn
      *c Hold

      Using SST, remove the 2 front differential case bearings (inner) from the differential case.

      SST
      09950-60010   ( 09951-00480 )
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09953-04020, 09958-04011 )

      Tech Tips

      Attach the claws of SST to the notch in the differential case assembly to secure SST.

  26. DISASSEMBLE DIFFERENTIAL CASE


    1. B003MIU

      Using a chisel and hammer, unstake the differential case.

    2. B003OSO

      Using a pin punch and hammer, tap out the straight pin.

    3. B003QEM

      Remove the following parts from the differential case.


      1. B003S4IC03
        *1 Differential Pinion Gear
        *2 Differential Pinion Gear Thrust Washer
        *3 Differential Pinion Shaft
        *4 Differential Side Gear
        *5 Differential Side Gear Thrust Washer

        Differential pinion gear (2 pieces)

      2. Differential pinion gear thrust washer (2 pieces)

      3. Differential pinion shaft

      4. Differential side gear (2 pieces)

      5. Differential side gear thrust washer (2 pieces)

  27. INSPECT DIFFERENTIAL GEAR KIT


    1. Check that the differential pinion and differential side gear are not damaged.


      • If the differential pinion or differential side gear is damaged, replace the differential gear kit.

  28. INSPECT FRONT DIFFERENTIAL CASE


    1. Check that the differential case is not damaged.


      • If the differential case is damaged, replace it.

  29. REMOVE FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING


    1. B003M1C

      Using a brass bar and hammer, tap out the 2 front differential side gear needle roller bearings.

  30. REMOVE DIFFERENTIAL CLUTCH HUB (w/ A.D.D.)


    1. B003KB8

      Using a snap ring expander, remove the side gear shaft hole snap ring.

    2. Remove the differential clutch hub.

  31. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL RH


    1. B003PTON01

      Using SST, tap out the differential side gear shaft oil seal RH from the front differential tube assembly.

      SST
      09308-00010

  32. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH


    1. B003NQB

      Using a snap ring pliers, remove the snap ring.

    2. Remove the differential side gear shaft sub-assembly RH from the front differential tube assembly.

  33. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT BEARING RH


    1. Using a snap ring expander, remove the snap ring.

    2. B003NVQN01

      Using SST, a brass bar and a press, press out the front differential side gear shaft bearing RH.

      SST
      09950-00020

      Note


      • Do not damage the front differential side gear shaft bearing RH.

      • Do not drop the differential side gear shaft sub-assembly RH.

  34. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL CLUTCH HUB (w/ A.D.D.)


    1. B003SBY

      Check that there is no wear or damage on the differential clutch hub and differential clutch sleeve.


      • If necessary, replace them.

    2. Check that the differential clutch sleeve slides smoothly on the differential clutch hub.

  35. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL SIDE GEAR INTER SHAFT (w/ A.D.D.)


    1. B003NGG

      Check that there is no wear or damage on the differential clutch sleeve and differential side gear inter shaft.

      If necessary, replace differential clutch sleeve and differential side gear inter shaft.

    2. Check that the differential clutch sleeve slides smoothly on the differential side gear inter shaft.

  36. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND CLUTCH SLEEVE FORK CLEARANCE (w/ A.D.D.)


    1. B003Q47

      Using a feeler gauge, measure the clearance between the clutch sleeve fork and differential clutch sleeve.

      Maximum clearance
      0.35 mm (0.0138 in.)

      • If the clearance is more than the maximum, replace the clutch sleeve fork or differential clutch sleeve.