FRONT DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY


  1. INSPECT DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH


    1. A01DUZOE01

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

      SST
      09564-33010
      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.

        Tech Tips

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

  2. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01E280E01
      Text in Illustration
      *a 30 mm (1.18 in.)

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

  3. REMOVE DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY


    1. A01DYFX

      Remove the 4 bolts.

    2. Using a hammer, pry out the actuator from the differential tube.

  4. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY


    1. A01DVXZ

      Remove the 4 bolts.

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

  5. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL LH


    1. A01DWJ8E01

      Using SST, tap out the oil seal.

      SST
      09308-00010

  6. REMOVE DIFFERENTIAL CLUTCH SLEEVE


    1. Remove the differential clutch sleeve.

  7. REMOVE DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY


    1. Remove the snap ring from the inter shaft.

    2. A01DXNBE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the inter shaft.

      SST
      09350-20015   ( 09369-20040 )
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011 )

  8. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR


    1. A01E2R6E01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, pry out the bearing retainer deflector.

      Tech Tips

      Tape the screwdriver tip before use.

  9. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT


    1. A01DVN5E01

      Using SST and a hammer, loosen the staked part of the nut.

      SST
      09930-00010   ( 09931-00010, 09931-00020 )
    2. A01DWE9E01
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09330-00021   ( 09330-00030 )

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


    1. A01E2D1E01

      Using SST, remove the companion flange with dust deflector.

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

      Note

      Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

  11. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL


    1. A01DZCPE01
      Text in Illustration
      *1 Oil Seal
      *2 Oil Slinger

      Using SST, remove the oil seal.

      SST
      09308-10010

  12. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. A01DZDA

      Remove the oil slinger from the drive pinion.

  13. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01DVWEE01

      Using SST, remove the roller bearing (inner) from the drive pinion.

      SST
      09556-22010

  14. REMOVE DIFFERENTIAL SIDE BEARING RETAINER


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

  15. REMOVE DIFFERENTIAL CASE ASSEMBLY

  16. REMOVE DIFFERENTIAL DRIVE PINION

  17. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. A01DZUG

      Remove the bearing spacer from the drive pinion.

  18. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01E1UME01

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

      SST
      09950-00020

      Note

      Do not drop the drive pinion.

      Tech Tips

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

  19. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. A01DVJ8

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

  20. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. A01DV6QE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the roller bearing (outer).

      SST
      09502-12010
      09612-65014   ( 09612-01020, 09612-01050 )

  21. REMOVE FRONT DIFFERENTIAL OIL STORAGE RING


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

  22. REMOVE FRONT DIFFERENTIAL CASE BEARING

    Tech Tips


    • Measure the thickness of the case washer.

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


    1. A01E2N8E01

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

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

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

    2. A01E0C9E01

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

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

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

  23. REMOVE DIFFERENTIAL RING GEAR


    1. A01DVNWE01
      Text in Illustration
      *1 Matchmark

      Place matchmarks on the ring gear and differential case.

    2. Remove the 10 ring gear set bolts.

    3. A01E1CO

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

  24. REMOVE FRONT DIFFERENTIAL CASE BEARING

    Tech Tips

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


    1. A01DWAPE01
      Text in Illustration
      *a Notch
      *b Turn
      *c Hold

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

      SST
      09950-60010   ( 09951-00480 )
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09953-04020, 09958-04011 )

      Tech Tips

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

  25. DISASSEMBLE DIFFERENTIAL CASE


    1. A01E020

      Using a chisel and hammer, unstake the differential case.

    2. A01DV08

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

    3. A01E0UI

      Remove the following parts from the differential case.


      • A01E1MEE01

        (1) 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)

  26. 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.

  27. INSPECT FRONT DIFFERENTIAL CASE


    1. Check that the differential case is not damaged.


      • If the differential case is damaged, replace it.

  28. REMOVE FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING


    1. A01E0O3

      Using a brass bar and hammer, tap out the 2 bearings.

  29. REMOVE DIFFERENTIAL CLUTCH HUB


    1. A01DVKG

      Using a snap ring expander, remove the snap ring.

    2. Remove the differential clutch hub.

  30. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL RH


    1. A01DXUTE01

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

      SST
      09308-00010

  31. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH


    1. A01E01C

      Using a snap ring expander, remove the snap ring.

    2. Remove the shaft from the differential tube.

  32. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING


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

    2. A01DXJIE01

      Using SST, a brass bar and a press, press out the shaft RH bearing.

      SST
      09950-00020

      Note


      • Do not damage the bearing.

      • Do not drop the shaft.

  33. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL CLUTCH HUB


    1. A01E2VR

      Check that there is no wear or damage on the clutch hub and clutch sleeve.


      • If necessary, replace them.

    2. Check that the clutch sleeve slides smoothly on the clutch hub.

  34. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL SIDE GEAR INTER SHAFT


    1. A01E1GW

      Check that there is no wear or damage on the clutch sleeve and side gear inter shaft.

      If necessary, replace clutch sleeve and side gear inter shaft.

    2. Check that clutch sleeve slides smoothly on the side gear inter shaft.

  35. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND CLUTCH SLEEVE FORK CLEARANCE


    1. A01E2SC

      Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve.

      Maximum clearance
      0.35 mm (0.0138 in.)

      • If the clearance is more than the maximum, replace the fork or clutch sleeve.