Replacement

DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER OIL SEAL (for AWD): REPLACEMENT

REPLACEMENT

1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. DRAIN DIFFERENTIAL OIL Testing and Inspection
3. REMOVE ENGINE ASSEMBLY
(a) Remove the engine assembly Removal.
4. INSTALL ENGINE ON TO ENGINE STAND Removal
5. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY Removal
6. FIX FRONT DIFFERENTIAL CARRIER ASSEMBLY TO OVERHAUL STAND Disassembly
7. REMOVE FRONT DIFFERENTIAL CARRIER RETAINER SUB-ASSEMBLY Disassembly
8. REMOVE NO. 1 FRONT DIFFERENTIAL CASE SUB-ASSEMBLY Disassembly
9. FIX DIFFERENTIAL CARRIER Disassembly
10. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT Disassembly
11. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY WITH DEFLECTOR Disassembly
12. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL





(a) Using SST, remove the oil seal from the differential carrier.
SST: 09308-00010
13. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER Disassembly
14. REMOVE DIFFERENTIAL DRIVE PINION WITH BEARING INNER RACE





(a) Remove the differential carrier together with the overhaul attachment from the engine stand.





(b) Install the differential carrier to the attachment as shown in the illustration.





(c) Using a press, remove the drive pinion from the differential carrier.
NOTE:
Do not drop the drive pinion or bearing inner race.

15. REPLACE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER





(a) Replace the drive pinion bearing spacer with a new one and install it to the drive pinion.
16. INSTALL DIFFERENTIAL DRIVE PINION WITH BEARING INNER RACE





(a) Using SST and the companion flange, install the drive pinion.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03040
09956-03060
HINT: Before using SST center bolt, apply hypoid gear oil to its threads and tip.

(b) Using SST, remove the companion flange.
17. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER Reassembly
18. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL





(a) Using SST and a hammer, tap in a new oil seal.
SST: 09309-36010
SST: 09502-24010
Standard depth:
6.2 to 7.2 mm (0.0244 to 0.0283 in.)
- Using a vernier caliper, measure the depth of the oil seal.
- Measure at 3 or more areas around the circumference of the oil seal
- Make sure the difference between the maximum and minimum measured values is less than 0.75 mm (0.0295 in.), as a greater difference may lead to oil leaks.
- Tap the oil seal uniformly so that the oil seal is straight.
- Do not excessively tap the oil seal.
HINT: First, uniformly tap in the oil seal until it is flush with the edge of the carrier, then tap it little by little until the depth is within the standard range.

(b) Apply MP grease to the lip of the oil seal.
19. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY WITH DEFLECTOR Reassembly
20. INSPECT DRIVE PINION PRELOAD Reassembly
21. INSTALL NO. 1 FRONT DIFFERENTIAL CASE SUB-ASSEMBLY Reassembly
22. INSTALL FRONT DIFFERENTIAL CARRIER RETAINER SUB-ASSEMBLY Reassembly
23. INSPECT TOTAL PRELOAD Reassembly
24. STAKE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT Reassembly
25. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY FROM OVERHAUL STAND Reassembly
26. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY Installation
27. INSTALL ENGINE TO VEHICLE
(a) Remove the engine from the engine stand and then install it to the vehicle Installation.
28. ADD DIFFERENTIAL OIL Testing and Inspection