DIFFERENTIAL CASE DISASSEMBLY

PROCEDURE

  1. REMOVE FRONT DIFFERENTIAL CASE OIL SEAL

    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. C318870N01

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

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  2. 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. C207064C01

      *a

      Matchmark

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

    3. C199117

      Remove the 12 bolts.

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

    5. Remove the front differential ring gear.

  3. INSPECT FRONT DIFFERENTIAL CASE

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  4. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

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  5. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

    1. C318873

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

  6. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT

    1. C207066

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

      09528-52010

      09953-05010

      09528-05010

      C318268C01

      *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. C318269C01

      *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.

      09528-52010

      09528-05030

      Note:

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

    3. C318270C01

      *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, 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.