FRONT DIFFERENTIAL CARRIER ASSEMBLY (for AWD) DISASSEMBLY


  1. SECURE FRONT DIFFERENTIAL CARRIER ASSEMBLY


    1. A01FIKO

      Set the front differential carrier assembly to an overhaul stand, etc. as shown in the illustration.

  2. INSPECT DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH


    1. A01FI2U

      Connect a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle.

    2. A01FG41E02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand.

      SST
      09564-32011
      Backlash
      0.08 to 0.16 mm (0.00315 to 0.00629 in.)

      If the backlash is not within the specified range, adjust the ring gear backlash or repair as necessary.

  3. INSPECT FRONT DRIVE PINION COMPANION FLANGE FRONT


    1. A01FETPE02
      Text in Illustration
      *a 37 mm (1.46 in.)

      Using a dial indicator, measure the runout of the companion flange vertically and horizontally.

      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 value, replace the companion flange.

  4. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD


    1. A01FIIVE01
      Text in Illustration
      *a Turn

      Using a torque wrench, measure the preload.

      Standard Preload (Starting Torque)
      0.5 to 0.8 N*m (5.1 to 8.1 kgf*cm, 4.4 to 7.0 in.*lbf)

  5. INSPECT TOTAL PRELOAD


    1. A01FIIVE01
      Text in Illustration
      *a Turn

      Using a torque wrench, measure the total preload.

      Standard Total Preload (Starting Torque)
      0.8 to 1.3 N*m (8.2 to 13.2 kgf*cm, 7.1 to 11.5 in.*lbf)

      If the total preload is not within the specified range, adjust the total preload or repair as necessary.

  6. REMOVE FRONT DIFFERENTIAL BREATHER PLUG


    1. A01FI2T

      Remove the front differential breather plug from the differential carrier.

  7. REMOVE FRONT DIFFERENTIAL CASE OIL SEAL LH


    1. A01FE8EE03
      Text in Illustration
      *1 Front Differential Case Oil Seal

      Using SST, remove the front differential case oil seal LH.

      SST
      09308-00010

  8. REMOVE FRONT DIFFERENTIAL CASE OIL SEAL RH

    Tech Tips

    Use the same procedure described for the LH side.

  9. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER


    1. A01FEGW

      Remove the 8 bolts.

    2. A01FF6X

      Using a brass bar and hammer, lightly tap the rib of the front differential side bearing retainer to remove it.

    3. Using a scraper and wire brush, clean the seal packing on the front differential carrier assembly and front differential side bearing retainer.

    4. Completely remove the oil with cleaning solvent.

  10. REMOVE FRONT DIFFERENTIAL CASE


    1. A01FDP1

      Remove the front differential case from the differential carrier.

  11. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01FEYR

      Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue.

    2. Install the differential case to the differential carrier.

    3. A01FEGW

      Install the differential side bearing retainer with the 8 bolts.

      Torque:
      58 N*m  { 590 kgf*cm, 43 ft.*lbf }

    4. Rotate the ring gear in both directions.

    5. Remove the 8 bolts and side bearing retainer.

    6. Remove the differential case from the differential carrier.

    7. Inspect the tooth contact pattern.

      A01FDE8E01
      Text in Illustration
      *a Proper Contact *b Heel Contact
      *c Face Contact *d Select an adjusting washer that will shift the drive pinion closer to the ring gear
      *e Toe Contact *f Flank Contact

  12. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT


    1. A01FI5XE01

      Using SST and a hammer, unstake the staked part of the front drive pinion companion flange front nut.

      SST
      09930-00010

      Note


      • Be sure to use SST with the tapered surface facing the shaft.

      • Do not grind the tip of SST with a grinder, etc.

      • Completely loosen the staked part of the nut when removing it.

      • Do not damage the threads of the drive pinion.

    2. A01FDGCE02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the flange, remove the front drive pinion companion flange front nut.

      SST
      09330-00021
      09950-30012   ( 09955-03030 )

      Note

      Apply grease to the threads and tip of SST center bolt before use.

  13. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT


    1. A01FEPEE02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the front drive pinion companion flange sub-assembly front.

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

      Note

      Apply grease to the threads and tip of SST center bolt before use.

  14. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR

    Tech Tips

    Perform this procedure only when the front differential dust deflector is damaged.


    1. A01FETZE03

      Using SST and a press, remove the front differential dust deflector.

      SST
      09950-00020
      09950-60010   ( 09951-00430 )
      09950-70010   ( 09951-07100 )

  15. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL


    1. A01FHZTE02
      Text in Illustration
      *1 Front Differential Carrier Oil Seal

      Using SST, remove the front differential carrier oil seal from the front differential carrier assembly.

      SST
      09308-00010

  16. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01FDVA

      Remove the front differential drive pinion oil slinger.

  17. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01FDO7E01
      Text in Illustration
      *1 Inner Race
      *a Turn
      *b Hold

      Using SST, remove the inner race of the front drive pinion rear tapered roller bearing from the drive pinion.

      SST
      09556-22010

      Note

      Apply grease to the threads and tip of SST center bolt before use.

  18. REMOVE DIFFERENTIAL DRIVE PINION


    1. Remove the differential drive pinion.

  19. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01FE1K

      Remove the front differential drive pinion bearing spacer.

  20. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR


    1. A01FEJX

      Remove the bolt and front differential side bearing retainer deflector.

  21. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01FEW7E03

      Using SST and a press, remove the inner race of the front drive pinion front tapered roller bearing from the drive pinion.

      SST
      09950-00020

      Tech Tips

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

    2. A01FFAXE02
      Text in Illustration
      *1 Adjust Shim
      *2 Outer Race
      *3 Concave Portion

      Using a brass bar and hammer, remove the outer race of the front drive pinion front tapered roller bearing and front adjust shim from the differential carrier assembly.

      Tech Tips

      Set the brass bar onto the concave portion of the differential carrier assembly. Lightly and uniformly tap the bearing and shim to remove them.

  22. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01FFZLE01
      Text in Illustration
      *1 Outer Race
      *2 Concave Portion

      Using a brass bar and hammer, remove the outer race of the front drive pinion rear tapered roller bearing from the differential carrier.

      Tech Tips

      Set the brass bar onto the concave portion of the differential carrier assembly. Lightly and uniformly tap the bearing and shim to remove them.

  23. REMOVE FRONT DIFFERENTIAL CASE BEARING


    1. A01FGSUE02
      Text in Illustration
      *1 Differential Case Plate Washer
      *2 Outer Race

      Using SST and a press, remove the outer race LH of the front differential case bearing and differential case plate washer from the differential carrier.

      SST
      09950-60010   ( 09951-00540, 09951-00550, 09952-06010 )
      09950-70010   ( 09951-07100 )

      Note

      Put identification marks on the case bearing outer race to distinguish between the RH side and LH side.

  24. REMOVE FRONT DIFFERENTIAL CASE BEARING


    1. A01FE4RE02
      Text in Illustration
      *1 Differential Case Plate Washer
      *2 Outer Race

      Using SST and a press, remove the outer race RH of the front differential case bearing and differential case plate washer from the differential side bearing retainer.

      SST
      09950-60010   ( 09951-00540, 09951-00550, 09952-06010 )
      09950-70010   ( 09951-07100 )

      Note

      Put identification marks on the case bearing outer race to distinguish between the RH side and LH side.

  25. REMOVE DIFFERENTIAL RING GEAR


    1. A01FF9FE02
      Text in Illustration
      *a Matchmarks

      Hold the front differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

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

    3. Using a screwdriver and a hammer, unstake the 4 lock plates.

    4. A01FDH9

      Remove the 8 ring gear set bolts and 4 lock plates.

    5. A01FJ1D

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

  26. REMOVE FRONT DIFFERENTIAL CASE BEARING

    Tech Tips

    Perform this procedure only when replacing the front differential case bearing or front differential case.


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

      Note

      Do not overtighten the vise.

    2. A01FEI0E02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the case bearing inner races LH and RH from the front differential case.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00300, 09951-00390, 09952-06010 )

      Note


      • Do not deform the bearing cage if the bearing is to be reused.

      • Attach the claws of SST to the bearing inner race from the cutout portions of the differential case.

      • Apply grease to the threads and tip of SST center bolt before use.

  27. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A01FGJ3E02
      Text in Illustration
      *1 Front Differential Pinion Shaft Straight Pin

      Using a 3 mm pin punch and hammer, remove the front differential pinion shaft straight pin.

    2. A01FJ2PE06
      Text in Illustration
      *1 Front Differential Pinion
      *2 Front Differential Pinion Thrust Washer
      *3 Front No. 1 Differential Pinion Shaft
      *4 Front Differential Side Gear
      *5 Front No. 1 Differential Side Gear Thrust Washer

      Remove the parts shown in the illustration from the differential case.

  28. INSPECT DIFFERENTIAL PINION AND SIDE GEAR


    1. Check that there is no damage to the differential pinion gear and side gear. If the differential pinion gear and/or side gear is damaged, replace them with new ones.

  29. INSPECT DIFFERENTIAL CASE


    1. Check that there is no damage to the differential case. If the differential case is damaged, replace it.