Disassembly

HINT: When fastening the differential carrier to an overhaul stand etc., fasten it at the 4 places on the ring gear side shown in the illustration.

1. Remove side gear shafts.
a. Using needle nose pliers, remove the 2 snap rings from the side gear shafts.





b. Using SST 09910 - 00015 (0991 1 - 0001 1, 09912 - 00010, 0991 4-0001 1), remove the 2 side gear shafts.

NOTICE: Be careful not to damage the oil seal.





2. Remove side oil seals. Using SST 09308 - 00010, remove the 2 side oil seals.

Fig. 4 Removing Snap Ring On Drive Pinion Side:

3. Remove snap ring on drive pinion side.
a. Install SST 09571 - 5001 0 on the differential carrier, as shown in the illustration.

Fig. 5 Dial Indicator Placement For Spreading Housing:

b. Install a dial indicator on the differential carrier, as shown in the illustration.
c. Tighten the SST bolt inward and spread the differential carrier 0.1 mm (0.004 inch) to make a gap between the side bearing outer race and the snap ring. Maximum: 0.2 mm (0.008 inch)

NOTICE: Pay attention to the needle of the dial indicator, being careful not to spread the differential carrier too far.





d. Using snap ring pliers, remove the snap ring on the drive pinion side.

HINT: Measure the snap ring and note the thickness for reassembly.

e. Remove the dial indicator and loosen the bolt of the SST.

HINT: Do not remove the SST.

Fig. 6 Snap Ring Removal:

4. Remove snap ring on ring gear side.
a. Using SST 09608 - 3201 0, 09950 - 70010 (09951 - 071 50) and a hammer, make a gap between the side bearing outer race and snap ring on the ring gear side.

HINT: Although the gap cannot be seen, 3 or 4 taps of the hammer on the SST are enough.





b. Using snap ring pliers, remove the snap ring on the ring gear side.

HINT: Measure the snap ring and note the thickness for reassembly.





5. Remove side bearing outer race on ring gear side. Tighten the SST bolt inward, pushing out the outer race on the ring gear side.

Fig. 8 Bearing Race Removal:

6. Remove side bearing outer race on drive pinion side.
a. Turn the opening in the differential case toward the opening in the differential carrier, as shown in the illustration.
b. Align the outer race with the indentation on the inside of the differential carrier, as shown in the illustration.





c. With lifting up the ring gear side of the differential case slowly, push the outer race out onto the differential case.

HINT: Tag the bearing outer races and snap rings to show the location for reassembly.





7. Remove differential case. Take the differential case out of the carrier with lifting the ring gear side, as shown in the illustration.
8. Remove drive pinion, spacer and companion flange.
a. Using a chisel and hammer, loosen the staked part of the nut.

Fig. 9 Pinion Flange Removal:

b. Using SST 09229 - 5501 0, 09330 - 00021, remove the nut.





c. Using a press, remove the drive pinion with the rear bearing and remove the companion flange.

NOTICE: Be careful not to drop the drive pinion.

d. Remove the spacer from the drive pinion.





9. Using SST 09308 - 00010, remove the front oil seal.
10. Remove oil slinger and front bearing.





11. Using SST 09950 - 00020 and a press, remove the rear bearing from the drive pinion.





12. Remove front and rear bearing outer races and adjusting plate washer.

NOTICE: Do not remove the outer race except when replacing the bearings. Using a brass bar and hammer, remove the 2 outs races and washer from the differential carrier.

HINT: Measure the washer and note the thickness for reassembly.





13. Remove side bearings. Using SST 09950 - 40010 (09951 - 04010, 09952 - 04010, 09953 - 04020, 09954 - 04010, 09955-04060), 09950 - 60010 (09951-00480), or equivalents, remove the 2 side bearings from the differential case.





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





15. 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 gears thrust washers