GSIC - Global Service Information Center

# FRONT DIFFERENTIAL CARRIER ASSEMBLY > DISASSEMBLY

## for Preparation Click here

1. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION

1. 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)
   1. 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

1. Using a dial indicator, measure the runout of the companion flange vertically and laterally.

   Maximum runout:

     Runout | Maximum
     Vertical runout | 0.10 mm (0.0039 in.)
     Lateral runout | 0.10 mm (0.0039 in.)

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

3. INSPECT DRIVE PINION PRELOAD

1. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

   Torque:
     Preload (at start of torque):
     0.49 to 0.78 N*m{ 5 to 8 kgf*cm , 4.3 to 6.9 in.*lbf }

4. INSPECT TOTAL PRELOAD

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

   Torque:
     Total preload (at start of torque):
     0.22 to 0.85 N*m{ 6 to 9 kgf*cm , 1.9 to 7.7 in.*lbf }
   1. If necessary, disassemble and inspect the differential.

5. REMOVE DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY

1. Remove the 4 bolts.

1. Using a hammer, pry out the actuator from the differential tube.

6. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY

1. Remove the 4 bolts.

1. Using a plastic-faced hammer, tap out the differential tube.

7. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

1. Using SST, tap out the oil seal.

   SST
     09308-00010

8. REMOVE DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY

1. Using SST, remove the inter shaft.

   SST
     09350-20015 (09369-20040)
     09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011)

1. Remove the snap ring from the inter shaft.

9. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR

1. Using a screwdriver, pry out the bearing retainer deflector.

   HINT:
     Tape the screwdriver tip before use.

10. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT

1. Using SST and a hammer, loosen the staked part of the nut.

   SST
     09330-00021

1. Using SST to hold the companion flange in place, remove the nut.

   SST
     09930-00010 (09931-00010, 09931-00020)

11. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

1. Using SST, remove the companion flange.

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

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

12. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR

1. Using SST and a press, press out the dust deflector.

   SST
     09950-00020
     09950-60010 (09951-00510)
     09950-70010 (09951-07150)

   NOTICE:
     Do not drop the companion flange.

13. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

1. Using SST, remove the oil seal from the differential carrier.

   SST
     09308-10010

14. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

1. Remove the oil slinger from the drive pinion.

15. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

1. Using SST, remove the roller bearing (inner) from the drive pinion.

   SST
     09556-22010

1. Remove the bearing spacer.

16. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

1. 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

1. Using SST and a press, press out the roller bearing (inner) from the drive pinion.

   SST
     09950-00020

   NOTICE:
     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

1. Using a brass bar and hammer, tap out the roller bearing (outer).

21. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

1. Using SST, remove the roller bearing (outer).

   SST
     09502-12010
     09612-65014 (09612-01020, 09612-01050)

22. REMOVE FRONT DIFFERENTIAL OIL STORAGE RING

1. Using a brass bar and hammer, tap out the oil storage ring.

23. REMOVE FRONT DIFFERENTIAL CASE BEARING

HINT:

1. Measure the thickness of the case washer.

1. Tag the bearing outer races to show the location for reassembly.

1. Using SST and a press, press out the case bearing (outer race) and plate washer from the bearing retainer.

   SST
     09950-60020 (09951-00680)
     09950-70010 (09951-07150)
   1. If the bearing is damaged during removal, replace it.

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

   SST
     09950-60020 (09951-00680)
     09950-70010 (09951-07150)
   1. If the bearing is damaged during removal, replace it.

24. REMOVE DIFFERENTIAL RING GEAR

1. Place matchmarks on the ring gear and differential case.

1. Remove the 10 ring gear set bolts.

1. Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.

25. REMOVE FRONT DIFFERENTIAL CASE BEARING

HINT:

  The differential case and case bearings should only be removed when replacement is necessary.

1. Using SST, remove the 2 case bearings (inner) from the differential case.

   SST
     09950-60010 (09951-00480)
     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

1. Using a chisel and hammer, unstake the differential case.

1. Using a pin punch and hammer, tap out the straight pin.

1. Remove the following parts from the differential case.

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

27. INSPECT DIFFERENTIAL GEAR KIT

1. Check that the differential pinion and differential side gear are not damaged.

   1. If the differential pinion or differential side gear is damaged, replace the differential gear kit.

28. INSPECT FRONT DIFFERENTIAL CASE

1. Check that the differential case is not damaged.

   1. If the differential case is damaged, replace it.

29. REMOVE FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING

1. Using a brass bar and hammer, tap out the 2 bearings.

30. REMOVE DIFFERENTIAL CLUTCH HUB

1. Using a snap ring expander, remove the snap ring.

1. Remove the differential clutch hub.

31. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

1. Using SST, tap out the oil seal from the differential tube.

   SST
     09308-00010

32. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH

1. Using a snap ring expander, remove the snap ring.

1. Remove the shaft from the differential tube.

33. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING

1. Using a snap ring expander, remove the snap ring.

1. Using SST, a brass bar and a press, press out the shaft RH bearing.

   SST
     09950-00020

   NOTICE:
   1. Do not damage the bearing.
   1. Do not drop the shaft.

34. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL CLUTCH HUB

1. Check that there is no wear or damage on the clutch hub and clutch sleeve.

   1. Replace parts as necessary.

1. 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

1. Check that there is no wear or damage on the clutch hub and side gear inter shaft.

   1. Replace parts as necessary.

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

36. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND CLUTCH SLEEVE FORK CLEARANCE

1. Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve.

   Maximum clearance:
     0.35 mm (0.0138 in.)
   1. If the clearance is greater than the maximum, replace the fork or clutch sleeve.