DIFFERENTIAL CASE DISASSEMBLY

PROCEDURE


  1. INSPECT FRONT DIFFERENTIAL CASE

    Click here

  2. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

    Click here

  3. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. Mount the front differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A005GIL

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

  4. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT


    1. A005IAP

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

  5. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

    Click here

  6. REMOVE FRONT DIFFERENTIAL SIDE GEAR


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

      SST
      09528-52010   ( 09953-05010, 09528-05020 )
      A005JJNE01
      Text in Illustration
      *a Turn *b Hold

      Note

      Do not overtighten SST, as doing so will damage the front differential side gear, conical spring, front differential side gear thrust washer and front differential case.

      Tech Tips


      • Tighten SST until there is a clearance between the front differential pinion and front differential side gear.

      • When removing the front differential pinion, do not overtighten SST, as it is necessary to rotate the front differential side gear.

    2. A005HO4E02
      Text in Illustration
      *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   ( 09528-05040 )

      Note

      Do not drop the front differential pinion and front differential pinion thrust washer.

    3. A005LKME02
      Text in Illustration
      *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 and conical spring.