Disassembly

DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY: DISASSEMBLY

DISASSEMBLY

1. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Using SST and a dial indicator, measure the ring gear backlash.
SST: 09564-32011
Standard:
0.11 to 0.21 mm (0.0043 to 0.0083 in.)
- If the backlash is not as specified, adjust the side bearing preload or repair as necessary.
HINT: Perform the measurements at 3 or more positions around the side bearing preload.

2. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Using a dial indicator, measure the runout of the companion flange vertically and laterally.
Maximum runout:

- If the runout is greater than the maximum, replace the companion flange.

3. INSPECT DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
HINT: Bolts without torque specifications are shown in the service data Service Data.

4. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
HINT: Bolts without torque specifications are shown in the service data Service Data.
- If necessary, disassemble and inspect the differential.

5. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Remove the 4 bolts.
(b) Using a hammer, pry out the actuator from the differential tube.

6. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY
(a) Remove the 4 bolts.
(b) Using a plastic-faced hammer, tap out the differential tube.

7. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST, tap out the oil seal.
SST: 09308-00010

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

9. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR
(a) Using a screwdriver with its tip wrapped in protective tape, pry out the bearing retainer deflector.
10. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT

(a) Using SST and a hammer, loosen the staked part of the nut.
SST: 09930-00010

(b) Using SST to hold the companion flange in place, remove the nut.
SST: 09330-00021

11. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Using SST, remove the companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03020
NOTE: Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

12. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR
(a) Using SST and a press, press out the dust deflector.
SST: 09950-00020
SST: 09950-60010
09951-00510
SST: 09950-70010
09951-07150
NOTE: Do not drop the companion flange.

13. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST, remove the oil seal from the differential carrier.
SST: 09308-10010
14. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Remove the oil slinger from the drive pinion.

15. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST, remove the roller bearing (inner) from the drive pinion.
SST: 09556-22010
(b) Remove the bearing spacer.
16. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
(a) Remove the 10 bolts and tap out the retainer with a plastic-faced hammer.
17. REMOVE DIFFERENTIAL CASE ASSEMBLY
18. REMOVE DIFFERENTIAL DRIVE PINION

19. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST and a press, press out the roller bearing (inner) from the drive pinion.
SST: 09950-00020
NOTE: Do not drop the drive pinion.
HINT: If the drive pinion or ring gear is damaged, replace them as a set.

20. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using a brass bar and hammer, tap out the roller bearing (outer).

21. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST, remove the roller bearing (outer).
SST: 09502-12010
SST: 09612-65014
09612-01020
09612-01050
22. REMOVE FRONT DIFFERENTIAL OIL STORAGE RING
(a) Using a brass bar and hammer, tap out the oil storage ring.
23. REMOVE FRONT DIFFERENTIAL CASE BEARING

HINT:
- Measure the thickness of the case washer.
- Tag the bearing outer races to show the location for reassembly.

(a) Using SST and a press, press out the case bearing (outer race) and plate washer from the bearing retainer.
SST: 09950-60020
09951-00680
SST: 09950-70010
09951-07150
- If the bearing is damaged during removal, replace it.

(b) Using SST and a press, press out the case bearing (outer race) and plate washer from the differential carrier.
SST: 09950-60020
09951-00680
SST: 09950-70010
09951-07150
If the bearing is damaged during removal, replace it.

24. REMOVE DIFFERENTIAL RING GEAR

(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 10 ring gear set bolts.

25. REMOVE FRONT DIFFERENTIAL CASE BEARING
HINT: The differential case and case bearings should only be removed when replacement is necessary.

(a) Using SST, remove the 2 case bearings (inner) from the differential case.
SST: 09950-60010
09951-00480
SST: 09950-40011
09951-04020
09952-04010
09953-04030
09954-04010
09955-04061
09953-04020
09958-04011
HINT: Fix the claws of SST to the notch in the differential case assembly.

26. DISASSEMBLE DIFFERENTIAL CASE

(a) Using a chisel and hammer, unstake the differential case.

(b) Using a pin punch and hammer, tap out the straight pin.

- (1) Differential pinion gear (2 pieces)
- (2) Differential pinion gear thrust washer (2 pieces)
- (3) Differential pinion shaft
- (4) Differential side gear (2 pieces)
- (5) Differential side gear thrust washer (2 pieces)

27. INSPECT DIFFERENTIAL GEAR KIT
(a) Check that the differential pinion and differential side gear are not damaged.
- If the differential pinion or differential side gear is damaged, replace the differential gear kit.

28. INSPECT FRONT DIFFERENTIAL CASE
(a) Check that the differential case is not damaged.
- If the differential case is damaged, replace it.

29. REMOVE FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING
(a) Using a brass bar and hammer, tap out the 2 bearings.

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

31. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST, tap out the oil seal from the differential tube.
SST: 09308-00010

32. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the shaft from the differential tube.

33. 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, press out the shaft RH bearing.
SST: 09950-00020
NOTICE:
- Do not damage the bearing.
- Do not drop the shaft.

34. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL CLUTCH HUB
(a) Check that there is no wear or damage on the clutch hub and clutch sleeve.
- Replace parts as necessary.

(b) Check that the clutch sleeve slides smoothly on the clutch hub.
Replace parts as necessary.

35. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL SIDE GEAR INTER SHAFT
(a) Check that there is no wear or damage on the clutch sleeve and side gear inter shaft.
- Replace parts as necessary.

(b) Check that the clutch sleeve slides smoothly on the side gear inter shaft.
Replace parts as necessary.

36. 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:
0.15 to 0.35 mm (0.0059 to 0.0138 in.)
- If the clearance is greater than the maximum, replace the fork or clutch sleeve.