FRONT DIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLY

PROCEDURE


  1. FIX FRONT DIFFERENTIAL CARRIER ASSEMBLY TO OVERHAUL STAND


    1. B006BZA

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

  2. REMOVE NO. 1 FRONT DIFFERENTIAL FILLER PLUG


    1. B006E4K

      Using a 10 mm socket hexagon wrench, remove the filler plug and gasket.

  3. REMOVE FRONT DIFFERENTIAL BREATHER PLUG


    1. B006AQY

      Remove the front differential breather plug from the differential carrier.

  4. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. B006GVJ

      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 differential ring gear at a right angle.

    2. B006A6LC01
      *a Turn
      *b Hold

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

      SST
      09564-50010
      Standard backlash
      0.15 to 0.23 mm (0.00591 to 0.00905 in.)

      Tech Tips


      • Measure at 3 or more areas around the circumference of the differential ring gear.

      • For reassembly purposes, record the result before disassembly.


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

  5. INSPECT RUNOUT OF FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY


    1. B006EBSC01
      *a Vertical Runout
      *b Lateral Runout
      *c 45.5 mm (1.79 in.)

      Wipe the inside surface of the companion flange with a cloth or equivalent and remove dirt and foreign matter.

    2. Perform the vertical runout inspection.


      1. Connect a lever probe to a dial indicator and set the probe at a right angle to the inner surface of the companion flange.

      2. Measure the vertical runout of the companion flange.

        Maximum runout
        0.12 mm (0.00472 in.)

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

        Tech Tips

        For reassembly purposes, record the result before disassembly.

    3. Perform the horizontal runout inspection.


      1. Set a dial indicator at a right angle to the surface of the companion flange as shown in the illustration.

      2. Measure the horizontal runout of the companion flange.

        Maximum runout
        0.08 mm (0.00315 in.)

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

        Tech Tips

        For reassembly purposes, record the result before disassembly.

  6. INSPECT DRIVE PINION PRELOAD


    1. B006DN5N01

      Using SST and a torque wrench, measure the drive pinion preload.

      SST
      09229-55010

      Tech Tips

      Record the drive pinion preload for the total preload inspection.

      Standard drive pinion preload (at starting)
      3.27 to 3.74 N*m (33.4 to 38.1 kgf*cm, 29.0 to 33.1 in.*lbf)

  7. INSPECT TOTAL PRELOAD


    1. B006DN5N01

      Using SST and a torque wrench, measure the preload with the teeth of the differential drive pinion and differential ring gear in contact.

      SST
      09229-55010
      Standard total preload
      3.87 to 4.61 N*m (39.5 to 47.0 kgf*cm, 34.3 to 40.8 in.*lbf)

  8. REMOVE FRONT DRIVE SHAFT OIL SEAL LH


    1. B006BVPN01

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

      SST
      09308-00010

  9. REMOVE FRONT DRIVE SHAFT OIL SEAL RH


    1. B0069KDN01

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

      SST
      09308-00010

  10. REMOVE FRONT DIFFERENTIAL CARRIER RETAINER SUB-ASSEMBLY


    1. B006C5A

      Loosen the 11 bolts.

    2. Remove the front differential carrier assembly from the overhaul attachment.

    3. Remove the 11 bolts.

    4. Insert the blade of an oil pan seal cutter between the differential carrier and front differential carrier retainer sub-assembly. Cut through the applied seal packing.

      Note

      Do not damage the installation surface of the differential carrier.

    5. Using a brass bar and hammer, lightly tap the front differential carrier retainer sub-assembly to remove it from the differential carrier.

      Note

      Do not damage the installation surface of the differential carrier.

  11. REMOVE NO. 1 FRONT DIFFERENTIAL CASE SUB-ASSEMBLY WITH RING GEAR


    1. B006GFI

      Remove the No. 1 differential case assembly from the differential carrier.

      Note

      Do not damage the 2 front differential case bearings and differential ring gear.

  12. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. B0069SK

      Uniformly apply a light coat of Prussian blue on both sides of 4 teeth on the differential ring gear.

    2. B006GFI

      Install the No. 1 front differential case sub-assembly with ring gear to the differential carrier.

    3. B006C5A

      Install the front differential carrier retainer sub-assembly with the 11 bolts.

      Torque:
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }
    4. B006B9V

      Rotate the companion flange several times in the forward and backward rotation directions.

    5. B006C5A

      Remove the 11 bolts and front differential carrier retainer sub-assembly.

    6. Remove the No. 1 front differential case sub-assembly with ring gear from the differential carrier.

    7. Inspect the tooth contact pattern.

      Tech Tips

      For reassembly purposes, record the result before disassembly.

      B006GNBC11
      *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 (*b, *c)
      *e Toe Contact *f Flank Contact
      *g Select an adjusting washer that will shift the drive pinion away from to the ring gear (*e, *f) - -

  13. FIX DIFFERENTIAL CARRIER


    1. B006AF2

      Fix the differential carrier to the overhaul stand.

  14. REMOVE FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    1. B006A1N

      Remove the 2 bolts and front differential breather plug oil deflector.

  15. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT


    1. B006DIMN01

      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. B006BDUN01

      Install SST to the flange as shown in the illustration.

      SST
      09213-58014
      09229-55010
      09330-00021

      Note


      • Use the 4 bolts with part number 90119-08B87.

      • Use bolts with a size of M6 x P1.25 with a bolt length beneath the head of 55 mm.

    3. B006AWSC01
      *a Turn
      *b Hold

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

      CAUTION:

      Secure the differential carrier so that it does not drop down.

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


    1. B006AJ7C01
      *a Turn
      *b Hold

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

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

      Tech Tips

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

  17. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR


    1. B006C3NN01

      Using SST and a press, press out the front differential dust deflector from the front drive pinion companion flange front sub-assembly.

      SST
      09950-00020
      09950-60010   ( 09951-00450 )
      09950-70010   ( 09951-07100 )

      Note


      • Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the front differential dust deflector.

      • Do not drop the front drive pinion companion flange front sub-assembly.

  18. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL

    Click here

  19. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. B006F8O

      Remove the front differential drive pinion oil slinger from the differential carrier.

  20. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING INNER RACE


    1. B006A89

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

    2. B006AYZC01
      *1 Differential Drive Pinion

      Using a press, press out the differential drive pinion.

      Note

      Do not drop the differential drive pinion.

    3. B006FUW

      Install the differential carrier to the overhaul attachment as it was installed previously.

    4. B006G1B

      Install the differential carrier together with overhaul attachment to the engine stand.

  21. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. B006AIC

      Remove the front differential drive pinion bearing spacer from the differential drive pinion.

  22. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B006E0R

      Remove the front drive pinion rear tapered roller bearing inner race from the differential carrier.

    2. B006G2BN01

      Using SST, remove the front drive pinion rear tapered roller bearing outer race from the differential carrier.

      SST
      09308-36010

      Note

      Do not damage the front differential carrier.

  23. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING INNER RACE


    1. B006A1GC01
      *a Nut

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

      SST
      09950-00020

      Note

      Do not drop the differential drive pinion.

      Tech Tips

      Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the front drive pinion front tapered roller bearing inner race.

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

    2. B006E2XC01
      *1 Front Drive Pinion Spacer Adjust Shim

      Using SST and a hammer, tap out the front drive pinion front tapered roller bearing outer race and front drive pinion spacer adjust shim from the differential carrier.

      SST
      09950-60011   ( 09951-00610, 09951-00650, 09952-06010 )
      09950-70010   ( 09951-07150 )

      Tech Tips

      For reassembly purposes, measure the thickness of the front drive pinion spacer adjust shim, and record the result.

  24. REMOVE FRONT DIFFERENTIAL CASE BEARING LH


    1. B006DGWC01
      *1 Differential Case Washer
      *2 Front Differential Case Bearing LH (Outer Race)

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

      SST
      09950-60011   ( 09951-00510, 09952-06010 )
      09950-60021   ( 09951-00680 )
      09950-70010   ( 09951-07100 )
    2. B006CQWC02
      *a Turn
      *b Hold

      Using SST, remove the front differential case bearing LH (inner race) from the No. 1 front differential case sub-assembly with ring gear.

      SST
      09950-40011   ( 09951-04020, 09953-04030, 09954-04010, 09955-04051, 09957-04010 )
      09950-60011   ( 09951-00460 )

      Note

      Before using SST center bolt (09953-04030), apply oil to its threads and tip.

  25. REMOVE FRONT DIFFERENTIAL CASE BEARING RH


    1. B006BFSC01
      *1 Differential Case Washer
      *2 Front Differential Case Bearing RH (Outer Race)

      Using SST and a press, press out the front differential case bearing RH (outer race) and differential case washer from the front differential carrier retainer sub-assembly.

      SST
      09950-60011   ( 09951-00520 )
      09950-70010   ( 09951-07100 )
    2. B006FTBC02
      *a Turn
      *b Hold
      *c Roller Cage
      *d Roller

      Using SST, remove the roller cage and bearing rollers.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04011, 09957-04010, 09958-04011 )

      Note

      Before using SST center bolt (09953-04030), apply oil to its threads and tip.

    3. B006CKLC02
      *a Turn
      *b Hold

      Using SST, remove the race from the No. 1 front differential case sub-assembly with ring gear.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04011, 09957-04010, 09958-04011 )
      09950-60011   ( 09951-00510 )

      Note

      Before using SST center bolt (09953-04030), apply oil to its threads and tip.

  26. REMOVE DIFFERENTIAL RING GEAR


    1. B006BC4C01
      *a Aluminum Plate

      Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. B006DFHC02
      *a Matchmark

      Put matchmarks on the differential ring gear and No. 1 front differential case sub-assembly.

    3. B0069PG

      Remove the 10 differential ring gear set bolts.

    4. Remove the differential case from the vise.

    5. B0069QK

      Using a plastic-faced hammer, tap on the differential ring gear to separate it from the No. 1 front differential case sub-assembly.

      Tech Tips

      Place a cloth on the tooth side of the differential ring gear to prevent damage.