Disassembly

FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

DISASSEMBLY





1. FIX 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





(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 with your hand.
SST 09564-32011
Backlash: 0.08 to 0.13 mm (0.0031 to 0.0512 in.)
If the backlash is not within the specified range, adjust the ring gear backlash or repair as necessary.





3. INSPECT FRONT DRIVE PINION COMPANION FLANGE FRONT
(a) Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
Maximum runout: 0.05 mm (0.0020 in.)
If the runout is greater than the maximum value, replace the companion flange.





4. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the total preload.
Total preload (at starting): 0.78 to 1.27 N*m (8.0 to 13.0 kgf*cm, 6.9 to 11.2 in.*lbf)
If the total preload is not within the specified range, adjust the total preload or repair as necessary.





5. REMOVE FRONT DIFFERENTIAL BREATHER PLUG
(a) Remove the differential breather plug from the differential carrier.





6. REMOVE FRONT DIFFERENTIAL CASE OIL SEAL
(a) Using SST, remove the 2 oil seals from the differential carrier.
SST 09308-00010
7. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT 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)

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





8. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT
(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 tip of the SST center bolt before use.

9. 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)





10. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST, remove the oil seal from the differential carrier.
SST 09308-10010

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

11. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Remove the drive pinion oil slinger.





12. 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 tip of the SST center bolt before use.





13. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Remove the drive pinion bearing spacer.
14. 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.
(d) Completely remove the oil with cleaning solvent.
15. REMOVE FRONT DIFFERENTIAL CASE
(a) Remove the differential case from the differential carrier.





16. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR
(a) Remove the bolt and differential side bearing retainer deflector.
17. REMOVE DIFFERENTIAL DRIVE PINION





18. 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

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





19. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) 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 onto the concave portion of the differential carrier assembly. Lightly and uniformly tap the bearing and shim to remove them.





20. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST, remove the outer race of the front drive pinion rear tapered roller bearing from the differential carrier.
SST 09502-12010, 09612-65014 (09612-01020, 09612-01050)

NOTICE:
^ Insert the SST into the outer race of the front drive pinion rear tapered roller bearing from the concave portion of the differential carrier assembly and engage the claws.
^ Apply grease to the threads and tip of the SST center bolt before use.





21. 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), 09950-70010 (09951-07150)

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





22. 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.

23. 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 screwdriver 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.
24. 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 09950-60010 (09951-00390), 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)

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 tip of the SST center bolt before use.

25. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN





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





(b) Remove the 2 differential pinions. [A]
(c) Remove the 2 differential pinion thrust washers. [B]
(d) Remove the differential pinion shaft. [C]
(e) Remove the 2 side gears. [D]
(f) Remove the 2 side gear thrust washers No. 1. [E]
26. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
(a) Check that there is no damage to the differential pinion gear and side gear. If the differential pinion gear and/or side gear is damaged, replace them with new ones.
27. INSPECT DIFFERENTIAL CASE
(a) Check that there is no damage to the differential case. If the differential case is damaged, replace it.