DIFFERENTIAL CASE DISASSEMBLY

PROCEDURE

1. REMOVE TRANSAXLE CASE OIL SEAL RH (INNER)

   1. 

      Using SST, remove the transaxle case oil seal RH (inner) from the front differential case.

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2. INSPECT FRONT DIFFERENTIAL CASE

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3. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

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4. REMOVE FRONT DIFFERENTIAL RING GEAR

   1. 

      *a

      Matchmark

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

   2. 

      Remove the 12 bolts from the front differential ring gear.

   3. 

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

5. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

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

      Note:

      Do not overtighten the vise.

   2. 

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

6. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT

   1. 

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

7. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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8. REMOVE FRONT DIFFERENTIAL SIDE GEAR

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

      

      *a

      Turn

      *b

      Hold

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      Note:

      Do not overtighten SST, as doing so will damage the 2 front differential side gears, 2 conical spring washers, 2 front No. 1 differential side gear thrust washers and front differential case.

      Tip:

      • Tighten SST until there is 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.

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      Note:

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

   3. 

      *1	Front Differential Side Gear
      *2	Conical Spring Washer
      *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 spring washers from the front differential case.

      Note:

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