Front Differential Disassembly

Front Differential Disassembly
Reference: Front Differential Dismounting and Remounting: Front - H27 Engine Model





1. Remove front drive shaft (1) from front drive shaft case (2) by using plastic hammer.





2. Remove axle lock actuator motor (1) and front drive shaft case (2) from differential housing (3) by removing bolts (4).





3. Remove front mounting bracket R (1) from differential housing (2) by removing bolts (3).





4. Remove 8 bolts (1, 2) and differential carrier cover for differential carrier.

NOTE: Loosen 8 mm thread diameter bolts (2) first, and then loosen 12 mm thread diameter bolts (1).

5. Remove axle lock actuator mounting bolts (1).





6. Take off differential side bearing outer races (2) and bevel gear with differential case (3).








7. Hold universal joint flange with special tool, and then remove flange nut by using socket wrench (2) and power wrench (3).
Special Tool
(B): 09922-66021

8. Make mating marks (1) on pinion and universal joint flange.

CAUTION: Do not make mating mark on the coupling surface of the flange.





9. Remove universal joint flange from pinion using special tool.
Special Tool
(C): 09913-65135





10. Remove pinion with front bearing and bearing pinion spacer from differential carrier. If it is hard to remove, screw an used nut into pinion and hammer on the nut with a plastic hammer but never directly on pinion.
11. Remove oil seal and take out rear bearing.





12. Using special tool, pull out differential side bearings.
Special Tool
(D): 09913-85230





13. With aluminum plates (3) placed on vise first, grip differential case with it and remove bevel gear (2) by removing bolts (1).

CAUTION: Use care not to hold axle lock clutch part with vise. Be sure to hold differential left case.








14. Separate differential case assembly by removing 2 screws (2) and take out free axle hub, differential gears and shims from differential left case (1).





15. Remove front bearing (2) from pinion (1) by using bearing puller (3) and hydraulic press.





16. Drive out pinion bearing outer races in differential carrier by hammering metal stick applied to them.