DIFFERENTIAL CASE DISASSEMBLY

PROCEDURE

  1. INSPECT FRONT DIFFERENTIAL CASE ASSEMBLY WITH RING GEAR

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  2. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

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  3. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

    1. Secure the front differential case assembly with ring gear in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

    2. C292459

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

  4. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT

    1. C263879

      Remove the front No. 1 differential pinion shaft from the front differential case assembly with ring gear.

  5. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

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  6. REMOVE FRONT DIFFERENTIAL SIDE GEAR

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

      C290763C03

      *a

      Turn

      *b

      Hold

      09528-52010

      09953-05010

      09528-05020

      Note:

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

      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. C290764C04

      *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 assembly with ring gear.

      09528-52010

      09528-05040

      Note:

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

    3. C304161C01

      *1

      Front Differential Side Gear

      *2

      Conical Spring

      *3

      Front No. 1 Differential Side Gear Thrust Washer

      Remove SST from the front differential case assembly with ring gear, and then remove the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs from the front differential case assembly with ring gear.

      Note:

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