DIFFERENTIAL CASE DISASSEMBLY

PROCEDURE

1. REMOVE FRONT DIFFERENTIAL RING GEAR

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

      Note:

      • Be careful not to damage the front differential ring gear.

      • Do not overtighten the vise.

   2. 

      *a

      Matchmark

      Put matchmarks on the front differential ring gear and front differential case sub-assembly.

   3. 

      Remove the 12 bolts.

   4. Using a plastic-faced hammer, remove the front differential ring gear from the front differential case sub-assembly.

2. INSPECT FRONT DIFFERENTIAL CASE SUB-ASSEMBLY

   Click hereClick here

3. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

   Click hereClick here

4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

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

      Note:

      • Be careful not to damage the front differential case sub-assembly.

      • Do not overtighten the vise.

   2. 

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

5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT

   1. 

      Remove the front No. 1 differential pinion shaft from the front differential case sub-assembly.

6. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

   Click hereClick here

7. REMOVE FRONT DIFFERENTIAL SIDE GEAR

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

      09528-52010

      09953-05010

      09528-05010

      

      *a

      Turn

      *b

      Hold

      Note:

      Do not overtighten SST, as doing so will damage the front differential side gear, center differential side gear conical spring washer, front No. 1 differential side gear thrust washer and front differential case.

      Tip:

      • Tighten SST until there is a clearance between the front differential pinions and front differential side gears.

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

   2. 

      *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 sub-assembly.

      09528-52010

      09528-05030

      Note:

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

   3. 

      *1	Front Differential Side Gear
      *2	Center Differential Side Gear Conical Spring Washer
      *3	Front No. 1 Differential Side Gear Thrust Washer

      Remove SST from the front differential case sub-assembly, and then remove the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 center differential side gear conical spring washers from the front differential case.

      Note:

      Do not drop the front differential side gear, front No. 1 differential side gear thrust washer and center differential side gear conical spring washer.