Disassembly

Front Differential Carrier Components:

Front Differential Carrier Components / w/o Differential Lock:

Front Differential Carrier Components / w/ Differential Lock:

1. w/ Differential lock: remove actuator.
a. Remove the bolt and actuator from the differential carrier.
b. Remove the O-ring.

2. w/ Differential lock: remove indicator switch. Remove the indicator switch and gasket.





3. w/ Differential lock: remove shift fork shaft.
a. Using a hexagon wrench, remove the 2 straight screw plugs.
b. Remove the spring seat, compression spring and ball.





c. Using a pin punch and hammer, remove the slotted spring pin.





d. Remove the 2 bolts from the shaft retainer.
e. Using a plastic hammer, tap out the shaft retainer.
f. Remove the shift fork shaft.

HINT: Pull out the shift fork shaft with a screwdriver turned round.

4. Remove companion flange.
a. Using a chisel and hammer, unstake the nut.





b. Using SST 09330-00021 to hold the flange, remove the nut and plate washer.





c. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020), remove the companion flange.





5. Remove oil seal and oil slinger.
a. Using SST 09308-10010, remove the oil seal from the differential carrier.
b. Remove the oil slinger.





6. Remove rear bearing. Using SST 09556-22010, remove the rear bearing from the drive pinion.





7. Remove differential case.
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the 2 adjusting nut locks.
c. Remove the 4 bolts and 2 bearing caps.
d. w/o Differential lock: Remove the 2 adjusting nuts.
e. w/o Differential lock: Remove the differential case with the side bearing outer races from the carrier.

HINT: Tag the disassembled parts to show the location for reassembly.

f. w/ Differential lock: Remove the differential case with the side bearing outer race, adjusting nuts and sleeve from the differential carrier.
g. w/ Differential lock: Remove the shift fork.

8. Remove drive pinion and bearing spacer.
a. Remove the drive pinion with the front bearing.
b. Remove the bearing spacer.





9. Remove drive pinion front bearing.
a. Using SST 0995-00020 and a press, remove the bearing from the drive pinion.

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

b. Remove the plate washer from the drive pinion.





10. Remove front and rear bearing outer races and oil storage ring.
a. Using SST 09308-00010, remove the rear bearing outer race.





b. Using a brass bar and hammer, remove the oil storage ring and front bearing outer race.

HINT: Do not remove the oil storage ring unless replacing it with a new one.

11. Remove ring gear.
a. Using a screwdriver and hammer, unstake the lock plate.





b. Place matchmarks on the ring gear and differential case.
c. Remove the ring gear 10 set bolts and 5 lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.





12. Check differential case runout.
a. Install the differential case in the differential carrier and tighten the adjusting nut just to where there is no play in the bearing.
b. Using a dial indicator, measure the differential case runout.

Maximum case runout: 0.07 mm (0.0028 inch)

c. Remove the differential case.





13. Remove side bearing from differential case. Using SST 09950-40010 (09951-04010, 09952-04020, 09953-04020, 09954-04010, 09955-04010, 09957-04010, 09958-04010), 09950-60010 (09951-00480), pull the side bearing from the differential case.

HINT: Fix the claws of SST to the notches in the differential case.





14. w/o Differential lock: Disassemble differential case.
a. Using a pin punch and hammer, remove the straight pin.
b. Remove these parts from the differential case:
^ Pinion shaft
^ 2 Pinion gears.
^ 2 Pinion gear thrust washers.
^ 2 Side gears.
^ 2 Side gear thrust washers.





15. w/ Differential lock: Disassemble differential case.
a. Place matchmarks on the LH and RH cases.
b. Remove the 8 bolts uniformly, a little at a time.
c. Using a plastic hammer, separate the LH and RH cases.
d. Remove these parts from the RH differential case:
^ 2 Side gears.
^ 2 Side gear thrust washers.
^ Spider.
^ 4 Pinion gears.
^ 4 Pinion gear thrust washers.