Disassembly

DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY: DISASSEMBLY

DISASSEMBLY

1. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION Front Differential Carrier Assembly

2. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY Front Differential Carrier Assembly

3. INSPECT DRIVE PINION PRELOAD Front Differential Carrier Assembly

4. INSPECT TOTAL PRELOAD Front Differential Carrier Assembly

5. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY






(a) Remove the 4 bolts.
(b) Using a plastic hammer, remove the differential tube.
6. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL






(a) Using SST, remove the oil seal.
SST: 09308-00010
7. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT






(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
8. 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
9. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR






(a) Using SST and a press, remove the dust deflector.
SST: 09950-00020
SST: 09950-60010
09951-00510
SST: 09950-70010
09951-07150
10. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL






(a) Using SST, remove the oil seal from the differential carrier.
SST: 09308-10010
11. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
12. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING






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






(a) Using SST and a press, remove the tapered roller bearing (inner) and washer from the drive pinion.
SST: 09950-00020
HINT: If the drive gear or ring gear is damaged, replace them as a set.

17. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING






(a) Using a brass bar and a hammer, remove the tapered roller bearing (outer).
18. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING






(a) Using SST, remove the rear tapered roller bearing (outer).
SST: 09502-12010
SST: 09612-65014
09612-01020
09612-01050
19. REMOVE FRONT DIFFERENTIAL OIL STORAGE RING
(a) Using a brass bar and a hammer, remove the oil storage ring.
20. REMOVE FRONT DIFFERENTIAL CASE BEARING
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 case bearing (outer) and plate washer from the bearing retainer.
SST: 09950-60020
09951-00680
SST: 09950-70010
09951-07150






(b) Using SST and a press, remove the case bearing (outer) and plate washer from the differential carrier assembly.
SST: 09950-60020
09951-00680
SST: 09950-70010
09951-07150
21. REMOVE DIFFERENTIAL RING GEAR






(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 10 bolts.
(c) Using a plastic hammer, tap on the ring gear to separate it from the differential case.
22. REMOVE FRONT DIFFERENTIAL CASE BEARING






(a) Using SST, remove the 2 differential case bearings (inner) from the differential case assembly.
SST: 09950-60010
09951-00480
SST: 09950-40011
09951-04020
09952-04010
09953-04030
09954-04010
09955-04061
09953-04020
09958-04011
23. DISASSEMBLE DIFFERENTIAL CASE






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






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






(c) 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
24. 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.
25. INSPECT FRONT DIFFERENTIAL CASE
(a) Check that the differential case assembly is not damaged.
If the differential case assembly is damaged, replace it.
26. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL






(a) Using SST, remove the oil seal from the differential tube.
SST: 09308-00010
27. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH






(a) Using a snap ring expander, remove the snap ring.
(b) Remove the side gear shaft from the differential tube.
28. 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 shaft RH bearing.
SST: 09950-00020
NOTE: Do not damage the bearing.