Part 1

FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

Components:

REMOVAL
1. DRAIN FRONT DIFFERENTIAL OIL
a) Remove the differential filler plug and gasket.
b) Remove the differential drain plug and gasket, and drain the oil.

2. REMOVE ENGINE ASSEMBLY
3. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY

a) Support the differential carrier with a jack.

NOTICE: Do not drop the differential carrier.

b) Remove the 3 bolts and differential carrier.

NOTICE:
^ Do not damage the installation surface when removing the differential carrier assembly.
^ The remaining oil may leak out when removing the differential carrier assembly.

DISASSEMBLY
1. SECURE FRONT DIFFERENTIAL CARRIER ASSEMBLY

a) Set the differential carrier to an overhaul stand, etc., as shown in the illustration.

2. INSPECT DIFFERENTIAL RING GEAR BACKLASH
3. INSPECT FRONT DRIVE PINION COMPANION FLANGE
4. INSPECT AND ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
5. INSPECT TOTAL PRELOAD
6. REMOVE FRONT DIFFERENTIAL BREATHER PLUG

a) Remove the differential breather plug from the differential carrier.

7. REMOVE FRONT DIFFERENTIAL CASE OIL SEAL

a) Using SST, remove the 2 oil seals from the differential carrier.
SST 09308-00010

8. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER

a) Remove the 8 bolts.

b) Using a brass bar and hammer, lightly tap the rib of the side bearing retainer to remove it.
c) Using a scraper and wire brush, clean the seal packing on the differential carrier sub-assembly and side bearing retainer.

NOTICE: Do not scratch the sealing surface.

d) Completely remove the oil with cleaning solvent.

9. REMOVE FRONT DIFFERENTIAL CASE

a) Remove the differential case from the differential carrier.

10. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
11. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT

a) Using SST and a hammer, unstake the staked part of the drive pinion nut.
SST 09930-00010

NOTICE:
^ Be sure to use the SST with the tapered surface facing the shaft.
^ Do not grind the tip of the SST with a grinder, etc.
^ Completely loosen the staked part of the nut when removing it.
^ Do not damage the threads of the drive pinion.

b) Using SST to hold the flange, remove the drive pinion nut.
SST 09330-00021, 09950-30012 (09955-03030)

12. REMOVE FRONT DRIVE PINION COMPANION FLANGE

a) Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

NOTICE: Apply grease to the threads and the tip of the SST center bolt before use.

13. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR

HINT: Perform this procedure only when the dust deflector is damaged.

a) Using SST and a press, remove the dust deflector.
SST 09950-00020, 09950-60010 (09951-00430), 09950-70010 (09951-07100)

14. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL

a) Using SST, remove the oil seal from the differential carrier.
SST 09308-00010

15. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

a) Remove the drive pinion oil slinger.

16. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

a) Using SST, remove the inner race of the front drive pinion rear tapered roller bearing from the drive pinion.
SST 09556-22010

NOTICE:
^ Apply grease to the threads and the tip of the SST center bolt before use.
^ Do not drop the drive pinion.

17. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

a) Remove the drive pinion bearing spacer.

18. REMOVE DIFFERENTIAL DRIVE PINION
a) Remove the differential drive pinion from the differential carrier.

NOTICE: Do not drop the drive pinion.

19. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR

a) Remove the bolt and differential side bearing retainer deflector.

20. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING

a) Using SST and a press, remove the inner race of the front drive pinion front tapered roller bearing from the drive pinion.
SST 09950-00020

NOTICE: Do not drop the drive pinion.

HINT: If either the drive pinion or the ring gear is damaged, replace both as a set.

b) Using a brass bar and hammer, remove the outer race of the front drive pinion front tapered roller bearing and front adjust shim from the differential carrier assembly.

HINT:
^ Set the brass bar into the concave portions of the differential carrier assembly Lightly and uniformly tap the bearing race and shim to remove them.
^ For reassembly purposes, measure the thickness of the adjust shim. Write down the result.

21. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

a) Using a brass bar and hammer, remove the outer race of the front drive pinion rear tapered roller bearing from the differential carrier assembly.

HINT: Set the brass bar onto the concave portion of the differential carrier assembly Lightly and uniformly tap the bearing race to remove it.

22. REMOVE FRONT DIFFERENTIAL CASE BEARING

a) Using SST and a press, remove the LH outer race of the front differential case bearing and case plate washer from the differential carrier.
SST 09950-60010 (09951-00540, 09951-00550, 09952-06010), 09950-70010 (09951-07100)

NOTICE: Put identification marks on the case bearing outer race to distinguish between the RH side and LH side.

HINT: For reassembly purposes, measure the thickness of the plate washer. Write down the result.

23. REMOVE FRONT DIFFERENTIAL CASE BEARING

a) Using SST and a press, remove the RH outer race of the front differential case bearing and case plate washer from the differential side bearing retainer.
SST 09950-60010 (09951-00540), 09950-70010 (09951-07150)

NOTICE: Put identification marks on the case bearing outer race to distinguish between the RH side and LH side.

HINT: For reassembly purposes, measure the thickness of the plate washer. Write down the result.

24. REMOVE DIFFERENTIAL RING GEAR

a) Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

b) Put matchmarks on the ring gear and differential case.
c) Using a chisel and a hammer, unstake the 4 lock plates.

d) Remove the 8 ring gear set bolts and 4 lock plates.

e) Using a plastic hammer, tap on the ring gear to separate it from the differential case.

NOTICE: Do not damage the ring gear.

25. REMOVE FRONT DIFFERENTIAL CASE BEARING

HINT: Perform this procedure only when replacing the case bearing or differential case.

a) Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

b) Using SST, remove the case bearing inner races LH and RH from the differential case.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00300, 09951-00390, 09952-06010)

NOTICE:
^ Do not deform the bearing cage if the bearing is to be reused.
^ Hook the SST claw from the dent of the differential case to the bearing inner race.
^ Apply grease to the threads and the tip of the SST center bolt before use.

26. REMOVE DIFFERENTIAL PINION AND SIDE GEAR

a) Using a pin punch (3 mm) diameter and hammer, remove the straight pin.

b) Remove the following parts from the differential case.

HINT:
^ Differential pinion: [A]
^ Differential pinion thrust washer: [B]
^ Differential pinion shaft: [C]
^ Differential side gear: [D]
^ Differential side gear thrust washer: [E]

c) Remove the differential pinion shaft from the differential case.

d) Remove the 2 differential pinions and 2 differential pinion thrust washers from the differential case.

e) Remove the 2 side gears and 2 side gear thrust washers from the differential case.

INSPECTION
1. INSPECT AND ADJUST DIFFERENTIAL RING GEAR BACKLASH

a) Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle.

b) Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange by hand.
SST 09564-32011
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0051 inch)

HINT:
^ Record the measured backlash to use as a reference for selecting a case washer.
^ Inspect tooth contact to use the result as a reference for selecting a case washer.
^ Select the case washer from the table so that the backlash is within the specified range, and install the selected washer.

c) If backlash is not within the specified range, change the thickness of the right and left case washers by equal amounts to adjust it.

Washer Thickness:

2. INSPECT FRONT DRIVE PINION COMPANION FLANGE

a) Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
Maximum runout: 0.05 mm (0.0020 inch)
If the runout is greater than the maximum value, replace the companion flange.

3. INSPECT DRIVEN PINION PRELOAD

a) Using a torque wrench, measure the preload using the backlash of the drive pinion and ring gear.
Preload (at starting):
New bearing: 0.98 to 1.57 Nm (10.0 to 16.0 kgf-cm, 8.7 to 13.9 inch lbs.)
Reused bearing: 0.49 to 0.78 Nm (5.0 to 8.0 kgf-cm, 4.3 to 6.9 inch lbs.)
If the drive pinion preload is not within the specified range, adjust the drive pinion preload or repair as necessary.

4. INSPECT TOTAL PRELOAD

a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
New bearing: 1.27 to 2.06 Nm (13.0 to 21.0 kgf-cm, 11.2 to 18.2 inch lbs.)
Reused bearing: 0.78 to 1.27 Nm (8.0 to 13.0 kgf-cm, 6.9 to 11.2 inch lbs.)
If the total preload is not within the specified range, adjust the total preload or repair as necessary.

5. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

a) Remove the 8 bolts and side bearing retainer.

b) Remove the differential case from the differential carrier.

c) Coat 3 or 4 teeth at the 3 different positions on the ring gear with red lead primer.
d) Install the differential case to the differential carrier.

e) Install the differential side bearing retainer with the 8 bolts.
Torque: 58 Nm (590 kgf-cm, 43 ft. lbs.)
f) Rotate the ring gear in both directions.
g) Remove the 8 bolts and side bearing retainer.
h) Remove the differential case from the differential carrier.

i) Inspect the tooth contact pattern.

j) If the teeth are not contacting properly, use the table to select a proper adjust shim for correction.

NOTICE:
^ If the contact pattern is either face contact or flank contact, the tooth contact may be adjustable while keeping the backlash within the specified range.
^ If the thickness of the front adjust shim has been changed, adjust the backlash and measure the total preload.

Washer Thickness:

6. INSPECT AND ADJUST DIFFERENTIAL SIDE GEAR BACKLASH

a) Hold the differential case in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

b) Measure the side gear backlash while holding 1 pinion gear toward the differential case.
Backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 inch)
If the backlash is not within the specified range, install the 2 side gear thrust washers of different thicknesses.

HINT: Refer to the table to select the 2 side gear thrust washers.

Washer Thickness:

7. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
a) Check that there is no damage to the differential pinion gears and side gears. If a differential pinion gear and/or side gear is damaged, replace them with new ones.

8. INSPECT DIFFERENTIAL CASE
a) Check that there is no damage to the differential case. If the differential case is damaged, replace it.