Part 1

DIFFERENTIAL CARRIER ASSY FRONT (4WD)











COMPONENTS

OVERHAUL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER SUB-ASSY NO.2 (W/ ENGINE UNDER COVER NO.2)
a. Remove the 4 bolts and engine under cover sub-assembly No.2.
4. REMOVE ENGINE UNDER COVER SUB-ASSY NO.1
a. Remove the 4 bolts and engine under cover sub-assembly No.1.
5. DRAIN DIFFERENTIAL OIL
6. REMOVE PROPELLER SHAFT ASSY FRONT
7. REMOVE FRONT AXLE HUB LH NUT
8. REMOVE FRONT AXLE HUB RH NUT
9. SEPARATE FRONT STABILIZER LINK ASSY LH
10. SEPARATE FRONT STABILIZER LINK ASSY RH
11. SEPARATE SPEED SENSOR FRONT LH
12. SEPARATE SPEED SENSOR FRONT RH
13. SEPARATE TIE ROD END SUB-ASSY LH
SST 09628-62011
14. SEPARATE TIE ROD END SUB-ASSY RH
SST 09628-62011
15. REMOVE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
16. REMOVE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
17. REMOVE FRONT DRIVE SHAFT ASSY LH
18. REMOVE FRONT DRIVE SHAFT ASSY RH





19. REMOVE DIFFERENTIAL CARRIER ASSY FRONT
a. Remove the bolt and separate the front differential breather tube bracket.
b. Support the front differential with a jack.
c. Remove the front differential mount nut No.1.
d. Remove the 2 front mounting bolts and 2 nuts.
e. Disconnect the actuator hose and connector.
f. Lower the jack and remove the front differential assembly.
g. Remove the 2 bolts and front differential support No.3.
h. Remove the 5 bolts and 2 front differential supports.





20. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION
a. Using SST and a dial indicator, measure the ring gear backlash.
SST 09564-32011
Backlash: 0.11 to 0.21 mm (0.0043 to 0.0083 inch)
If the backlash is not within the specification, adjust or repair the side bearing preload as necessary.





21. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. 0.49 to 0.78 Nm (5 to 8 kgf-cm, 4.3 to 6.9 inch lbs.)
If necessary, disassemble and inspect the differential assy.
22. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus 0.22 to 0.88 Nm (2.2 to 8.8 kgf-cm, 2.0 to 7.8 inch lbs.)
If necessary, disassemble and inspect the differential.





23. REMOVE DIFFERENTIAL VACUUM ACTUATOR ASSY
a. Remove the 4 bolts.
b. Using a hammer handle, remove the actuator assembly.





24. REMOVE FRONT DIFFERENTIAL TUBE ASSY
a. Remove the 4 bolts.
b. Using a plastic hammer, remove the differential tube.





25. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST, remove the oil seal.
SST 09308-00010





26. REMOVE DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSY
a. Using SST, remove the side gear inter shaft.
SST 09350-20015 (09369-20040), 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011)
b. Remove the snap ring from the side gear inter shaft.





27. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSY FRONT
a. Using SST and a hammer, remove the nut.
SST 09930-00010





b. Using SST to hold the companion flange, remove the nut.
SST 09330-00021





c. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)





28. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL
a. Using SST, remove the oil seal from the differential carrier assembly.
SST 09308-10010
29. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER





30. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST, remove the rear bearing from the drive pinion.
SST 09556-22010
b. Remove the bearing spacer.
31. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
a. Using a screwdriver, remove the union.
b. Remove the 10 bolts and tap out the side bearing retainer with a plastic hammer.
32. REMOVE DIFFERENTIAL CASE ASSY
33. REMOVE DIFFERENTIAL DRIVE PINION





34. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST and a press, remove the front bearing and washer from the drive pinion.
SST 09950-00020

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





35. REMOVE FRONT BEARING OUTER RACE
a. Using a brass bar and a hammer, remove the front bearing outer race.





36. REMOVE REAR BEARING OUTER RACE
a. Using SST, remove the rear bearing outer race.
SST 09502-12010, 09612-65014 (09612-01020, 09612-01050)
b. Using a brass bar and a hammer, remove the oil storage ring.

37. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR
a. Using a brass bar and hammer, remove the side bearing retainer deflector by tapping it gently.





38. REMOVE SIDE BEARING OUTER RACE

HINT:
^ Measure the plate washer and note its thickness.
^ Tag the bearing outer races to show the location for reassembly.

a. Using SST and a press, remove the outer race and plate washer from the bearing retainer.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)





b. Using SST and a press, remove the outer race and plate washer from the differential carrier assembly.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)
39. REMOVE DIFFERENTIAL RING GEAR
a. Place matchmarks on the ring gear and differential case assembly.
b. Remove the 10 bolts.
c. Using a plastic hammer, tap on the ring gear to separate it from the differential case assembly.





40. REMOVE FRONT DIFFERENTIAL CASE BEARING
a. Using SST, remove the 2 differential case bearings from the differential case assembly.
SST 09950-60010 (09951-00390), 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)

HINT: Fix the claws of SST into the notch in the differential case assembly.





41. DISASSEMBLE DIFFERENTIAL CASE
a. Using a pin punch and a hammer, remove the straight pin.
b. Remove these parts from the differential case assembly.
(1) 2 Differential side gears
(2) 2 Differential side gear thrust washers
(3) Differential pinion shaft
(4) 2 Differential pinion gears
(5) 2 Differential pinion gear thrust washers
42. INSPECT DIFFERENTIAL GEAR KIT
a. Check that there is no damage to the pinion gear and side gear.
If the pinion gear and/or side gear is damaged, replace the differential gear kit.
43. INSPECT FRONT DIFFERENTIAL CASE
a. Check that the differential case assembly is not damaged.
If the differential case assembly is damaged, replace it.





44. REMOVE FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING
a. Using a brass bar and hammer, remove the 2 bearings.





45. REMOVE DIFFERENTIAL CLUTCH HUB
a. Using a snap ring expander, remove the snap ring.
b. Remove the differential clutch hub.





46. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST, remove the oil seal from the differential tube.
SST 09308-00010





47. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY RH
a. Using a snap ring expander, remove the snap ring.
b. Remove the side gear shaft from the differential tube.





48. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING
a. Using a snap ring expander, remove the snap ring.
b. Using SST, a brass bar and a press, remove the bearing.
SST 09950-00020

NOTICE: Do not damage the bearing.





49. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR
a. Using SST, a socket wrench and a press, remove the dust deflector.
SST 09950-00020





50. REMOVE DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL CLUTCH HUB
a. Check for wear and damage to the clutch hub and clutch sleeve.
If necessary, replace them.
b. Check that the clutch sleeve slides smoothly on the clutch hub.





51. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND CLUTCH SLEEVE FORK CLEARANCE
a. Check for wear and damage to the clutch hub and side gear inter shaft.
b. Check that the clutch sleeve slides smoothly on the side gear inter shaft.





52. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND CLUTCH SLEEVE FORK CLEARANCE
a. Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve.
Maximum clearance: 0.35 mm (0.0138 inch)
If the clearance exceeds the maximum, replace the fork or clutch sleeve.





53. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR
a. Using a steel plate and a press, install a new dust deflector.

NOTICE: Do not damage the dust deflector.





54. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING
a. Using SST and a press, install the bearing.
SST 09223-00010
b. Using a snap ring expander, install the snap ring.





55. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSY RH
a. Install the side gear shaft into the differential tube.
b. Using snap ring pliers, install the snap ring.





56. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
a. Using SST and a plastic hammer, install a new oil seal.
SST 09608-32010
Oil seal drive in depth: 5.3 - 0.5 mm (0.2087 - 0.0197 inch)
b. Coat the oil seal lip with MP grease.





57. INSTALL DIFFERENTIAL CLUTCH HUB
a. Install the clutch hub onto the side gear inter shaft.
b. Using snap ring pliers, install the snap ring.

NOTICE: Be sure to install the differential clutch hub in the correct direction.





58. INSTALL FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING
a. Using SST and a press, install 2 new bearings.
SST 09950-60010 (09951-00380)
Bearing press in depth: 1.7 - 0.3 mm (0.067 - 0.012 inch)





59. INSTALL FRONT DIFFERENTIAL CASE
a. Install the 2 proper thrust washers onto the 2 side gears.

HINT: Using the table, select a thrust washer which will ensure that the backlash is within the specifications.





Washer thickness

b. Install the 2 side gears, 2 side gear thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft into the differential case assembly.

HINT: Align the holes of the differential case assembly and pinion shaft.

c. Measure the side gear backlash.





(1) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case assembly.
Backlash: 0 to 0.15 mm (0 to 0.0059 inch)
If the backlash is not within the specification, install a side gear thrust washer with a different thickness.





d. Using a pin punch and hammer, install the straight pin through the differential case assembly and hole of the pinion shaft.
e. Stake the differential case assembly.





60. INSTALL DIFFERENTIAL RING GEAR
a. Clean the contact surfaces of the differential case assembly and ring gear.
b. Heat the ring gear to about 100°C (212°F) in boiling water.
c. Carefully take the ring gear out of the boiling water.
d. After any moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case assembly.

HINT: Align the matchmarks on the ring gear and differential case assembly.

e. Temporarily install 10 bolts so that the bolt holes in the ring gear and differential case assembly are aligned.
f. After the ring gear has cooled sufficiently, tighten the ring gear set bolts to which thread lock has been applied.
Torque: 97 Nm (984 kgf-cm, 71 ft. lbs.)
Thread lock: Part No.08833-00100, THREE BOND 1360k or equivalent