FRONT DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY


  1. REMOVE DIFFERENTIAL EXTENSION FLANGE TUBE


    1. A015AC3

      Remove the 4 bolts.

    2. Using a plastic-faced hammer, remove the differential tube.

  2. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A0158O1E02

      Using SST, tap out the oil seal.

      SST
      09308-00010

  3. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT


    1. A015560E02

      Using SST and a hammer, unstake the nut.

      SST
      09930-00010
    2. A015C24E02

      Using SST to hold the companion flange, remove the nut.

      SST
      09330-00021   ( 09330-00030 )

  4. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A0155P9E04

      Using SST, remove the companion flange from the differential carrier.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020 )

  5. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL


    1. A0157D1E02

      Using SST, remove the oil seal.

      SST
      09308-10010

  6. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

  7. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER


    1. A01564FE01

      Remove the bolts labeled B and front differential front support assembly LH.

    2. Remove the bolts labeled A.

    3. Using a plastic-faced hammer, tap out the bearing retainer.

  8. REMOVE FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY


    1. Remove the differential case from the differential carrier.

  9. REMOVE DIFFERENTIAL DRIVE PINION


    1. A0159S4E02

      Set the differential carrier to an overhaul stand as shown in the illustration.

    2. Using a press, press out the drive pinion.

      Note

      Do not drop the drive pinion.

  10. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING


    1. Remove the bearing (inner race) from the differential carrier.

  11. REMOVE FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. A0157O9

      Remove the 2 bolts and oil deflector.

  12. REMOVE FRONT DIFFERENTIAL UNION


    1. A015AH3

      Remove the front differential union from the differential carrier.

  13. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A015B45E01

      Using SST and a press, press out the bearing (inner race) from the drive pinion.

      SST
      09950-00020

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

  14. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A015DX0

      Using a brass bar and hammer, tap out the bearing (outer race) and washer.

  15. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING


    1. A015BW9E02

      Using SST and a hammer, tap out the bearing (outer race) from the differential carrier.

      SST
      09950-70010   ( 09951-07100 )
      09950-60010   ( 09951-00450 )
      09950-60020   ( 09951-00710, 09952-06010 )

  16. REMOVE FRONT DIFFERENTIAL CASE BEARING

    Tech Tips


    • Measure the plate washer and note its thickness.

    • Tag the bearing outer races to show the location for reassembly.


    1. A0157UUE02

      Using SST and a press, press out the bearing (outer race) and plate washer from the bearing retainer.

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07150 )
    2. A0159FLE02

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

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

  17. REMOVE DIFFERENTIAL RING GEAR


    1. A0156K7E02

      Place matchmarks on the ring gear and differential case.

    2. Remove the 12 bolts.

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

  18. REMOVE FRONT DIFFERENTIAL CASE BEARING


    1. A01588TE02

      Using SST, remove the 2 bearings (inner race).

      SST
      09950-60010   ( 09951-00390 )
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )

      Tech Tips

      Fix the claws of SST into the notch in the differential case assembly.

  19. DISASSEMBLE DIFFERENTIAL CASE


    1. A0159OFE02

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

    2. Remove these parts from the differential case assembly.


      1. 2 differential side gears

      2. 2 differential side gear thrust washers

      3. Differential pinion shaft

      4. 2 differential pinion gears

      5. 2 differential pinion gear thrust washers

  20. INSPECT DIFFERENTIAL GEAR KIT


    1. Check that there is no damage to the pinion gears and side gears.

      If a pinion gear and/or side gear is damaged, replace the differential gear kit.

  21. INSPECT FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY


    1. Check that the differential case is not damaged.

      If the differential case is damaged, replace it.

  22. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    1. A015E5BE03

      Using SST, tap out the oil seal from the flange tube.

      SST
      09308-00010

  23. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH


    1. A0158XO

      Using a snap ring pliers, remove the snap ring.

    2. A0159GH

      Using a plastic-faced hammer, tap out the side gear shaft.

  24. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING


    1. A0156VI

      Using a snap ring expander, remove the snap ring.

    2. A0158ZEE03

      Using SST and a press, press out the bearing.

      SST
      09950-00020
      09950-70010   ( 09951-07100 )
      09950-60010   ( 09951-00450 )

      Note

      Do not damage the bearing.

  25. REMOVE FRONT DIFFERENTIAL CARRIER STRAIGHT PIN


    1. A0156KT

      Remove the straight pins from the bearing retainer.

  26. REMOVE FRONT DIFFERENTIAL TUBE STRAIGHT PIN


    1. A015DGE

      Remove the straight pins from the bearing retainer.