FRONT DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY

PROCEDURE

  1. INSPECT DIFFERENTIAL RING GEAR BACKLASH

    C258277N01

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

      09564-32011

      Standard 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.

      Tip:

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

  2. INSPECT FRONT DRIVE PINION COMPANIONFLANGE SUB-ASSEMBLY

    C258278C01

    *a

    Vertical Runout

    *b

    Lateral Runout

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

      Distance from center to runout measurement point

      30 mm (1.18 in.)

      Maximum Runout

      Item

      Specified Condition

      Vertical runout

      0.15 mm (0.00591 in.)

      Lateral runout

      0.15 mm (0.00591 in.)

      If the runout is more than the maximum, replace the companion flange.

  3. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY

    1. C258378

      Using an E14 "TORX" socket wrench, remove the 4 bolts.

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

  4. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

    1. C258279N01

      Using SST, remove the 2 oil seals.

      09308-00010

  5. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT

    C258280N01

    1. Using SST and a hammer, unstake the nut.

      09930-00010

    2. C258281N01

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

      09330-00021

      09330-00030

  6. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

    C258282C01

    *a

    Hold

    *b

    Turn

    1. Using SST, remove the companion flange.

      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.

  7. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR

    C258283N01

    1. Using SST and a press, press out the dust deflector.

      09950-00020

      09950-60010

      09951-00510

      09950-70010

      09951-07150

      Note:

      Do not drop the companion flange.

  8. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL

    1. C258284N01

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

      09308-10010

  9. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

    1. Remove the oil slinger from the drive pinion.

  10. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (INNER)

    1. C310120N01

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

      09556-22010

  11. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (OUTER)

    1. C310121N01

      Using SST, remove the front tapered roller bearing (outer).

      09308-00010

  12. REMOVE FRONT DIFFERENTIAL OIL STORAGE RING

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

  13. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

    C258265

    1. Remove the bearing spacer.

  14. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

    1. Using a screwdriver, remove the union.

    2. Remove the 10 bolts and tap out the side bearing retainer with a plastic-faced hammer.

  15. REMOVE DIFFERENTIAL CASE ASSEMBLY

  16. REMOVE DIFFERENTIAL DRIVE PINION

  17. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (INNER)

    1. C258287N01

      Using SST and a press, remove the rear tapered roller bearing (inner) and washer from the drive pinion.

      09950-00020

      Note:

      Do not drop the drive pinion.

      Tip:

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

  18. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER)

    1. C258285

      Using a brass bar and hammer, remove the rear tapered roller bearing (outer).

  19. REMOVE FRONT DIFFERENTIAL CASE BEARING

    C258288N01
    Tip:

    • Measure the thickness of the case washer.

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

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

      09950-60020

      09951-00680

      09950-70010

      09951-07150

      If the bearing is damaged during removal, replace it.

    2. C258289N01

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

      09950-60020

      09951-00680

      09950-70010

      09951-07150

      If the bearing is damaged during removal, replace it.

  20. REMOVE DIFFERENTIAL RING GEAR

    C113176C01

    *1

    Matchmark

    1. Place matchmarks on the ring gear and differential case.

    2. Remove the 10 ring gear set bolts.

    3. C258290

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

  21. REMOVE FRONT DIFFERENTIAL CASE BEARING

    Tip:

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

    1. C258291C01

      *1

      Notch

      *a

      Turn

      *b

      Hold

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

      09950-60010

      09951-00390

      09950-40011

      09951-04020

      09952-04010

      09953-04030

      09954-04010

      09955-04061

      09957-04010

      09958-04011

      Tip:

      Set the claws of SST into the notches in the differential case.

  22. REMOVE DIFFERENTIAL CASE ASSEMBLY

    1. C258292

      Using a chisel and hammer, unstake the differential case.

    2. C258293

      Using a 5 mm pin punch and hammer, tap out the straight pin.

    3. C258294C02

      *1

      Differential Pinion Gear

      *2

      Differential Pinion Gear Thrust Washer

      *3

      Differential Pinion Shaft

      *4

      Differential Side Gear

      *5

      Differential Side Gear Thrust Washer

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

  23. 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.

  24. INSPECT FRONT DIFFERENTIAL CASE

    1. Check that the differential case is not damaged.

      If the differential case is damaged, replace it.

  25. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

    1. C258295N01

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

      09308-00010

  26. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH

    1. C258286

      Using a snap ring expander, remove the snap ring.

    2. Remove the side gear shaft from the differential tube.

  27. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT BEARING RH

    1. C258296N01

      Using a snap ring expander, remove the snap ring.

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

      09950-00020

      Note:

      • Do not damage the bearing.

      • Do not drop the shaft.