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FRONT DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY

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PROCEDURE


  1. Click here

    INSPECT DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH


    1. B0024TYN04

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

      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.

        Tip:

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

  2. Click here

    INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. B002716C05
      *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. Click here

    REMOVE OIL TEMPERATURE SENSOR


    1. A01WALM

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

  4. Click here

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


    1. B0025HK

      Remove the 4 bolts.

    2. B0025BR

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

  5. Click here

    REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY


    1. A01W8H4

      w/ A.D.D.


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

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

    2. A01W8NH

      w/o A.D.D.


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

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

  6. Click here

    REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL LH


    1. B0024DIN01

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

      09308-00010
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    REMOVE DIFFERENTIAL CLUTCH SLEEVE (w/ A.D.D.)


    1. Remove the differential clutch sleeve.

  8. Click here

    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. B0027SSC02
      *a Turn
      *b Hold

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

      09350-20015 09369-20040
      09950-40011 09951-04010 09952-04010 09953-04020 09954-04010 09955-04011 09957-04010 09958-04011
  9. Click here

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


    1. B0025WJC04
      *a Protective Tape

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

      Tip:

      Tape the screwdriver tip before use.

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    REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT

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  11. Click here

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

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  12. Click here

    REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL

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  13. Click here

    REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

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  14. Click here

    REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B00277TN01

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

      09556-22010
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    REMOVE DIFFERENTIAL SIDE BEARING RETAINER


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

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    REMOVE FRONT DIFFERENTIAL UNION


    1. Remove the front differential union from the differential side bearing retainer.

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    REMOVE DIFFERENTIAL CASE ASSEMBLY

  18. Click here

    REMOVE DIFFERENTIAL DRIVE PINION

  19. Click here

    REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

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    REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B0026NSN01

      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.

      09950-00020
      Note:

      Do not drop the differential drive pinion.

      Tip:

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

  21. Click here

    REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B00245SC02
      *a Turn
      *b Hold

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

      09502-12010
      09612-65014 09612-01020 09612-01050
  22. Click here

    REMOVE FRONT DIFFERENTIAL OIL STORAGE RING


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

  23. Click here

    REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01SCMS

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

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    REMOVE FRONT DIFFERENTIAL CASE BEARING

    Tip:

    • Measure the thickness of the case washer.

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


    1. B0026EHN02

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

      09950-60020 09951-00680
      09950-70010 09951-07150

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

    2. B0028TLN02

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

      09950-60020 09951-00680
      09950-70010 09951-07150

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

  25. Click here

    REMOVE DIFFERENTIAL RING GEAR


    1. B0026GDC01
      *a Matchmark

      Place matchmarks on the differential ring gear and differential case.

    2. Remove the 10 bolts.

    3. A01SDLD

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

  26. Click here

    REMOVE FRONT DIFFERENTIAL CASE BEARING

    Tip:

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


    1. B0024PIC02
      *a Notch
      *b Turn
      *c Hold

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

      09950-60010 09951-00480
      09950-40011 09951-04020 09952-04010 09953-04030 09954-04010 09955-04061 09953-04020 09958-04011
      Tip:

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

  27. Click here

    DISASSEMBLE DIFFERENTIAL CASE


    1. A01SBSF

      Using a chisel and hammer, unstake the differential case.

    2. A01SEJJ

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

    3. A01W9F7

      Remove the following parts from the differential case.


      1. B0024K7C03
        *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)

  28. Click here

    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.

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    INSPECT FRONT DIFFERENTIAL CASE


    1. Check that the differential case is not damaged.


      • If the differential case is damaged, replace it.

  30. Click here

    REMOVE FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING


    1. A01SEPV

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

  31. Click here

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


    1. A01SBDR

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

    2. Remove the differential clutch hub.

  32. Click here

    REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL RH


    1. B0028SMN01

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

      09308-00010
  33. Click here

    REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH


    1. A01W8DA

      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.

  34. Click here

    REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT BEARING RH


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

    2. B00291TN01

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

      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.

  35. Click here

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


    1. A01SBNC

      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.

  36. Click here

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


    1. A01SE60

      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.

  37. Click here

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


    1. A01SBDS

      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.