Disassembly

DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for AWD): DISASSEMBLY

1. FIX FRONT DIFFERENTIAL CARRIER ASSEMBLY TO OVERHAUL STAND

(a) Set the differential carrier to an overhaul stand 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 : 09564-50010

Standard backlash:

0.13 to 0.23 mm (0.00512 to 0.00905 in.)

HINT
* Measure at 3 or more areas around the circumference of the ring gear.
* For reassembly purposes, record the result before disassembly.

If the backlash is not within the specified range, adjust the ring gear backlash or repair as necessary.

3. INSPECT RUNOUT OF FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY

(a) Wipe the inside surface of the companion flange with a cloth or equivalent and remove dirt and foreign matter.

(b) Perform the vertical runout inspection.

(1) Set a lever probe to a dial indicator and set the probe at a right angle to the inner surface of the companion flange.

(2) Measure the vertical runout of the companion flange.

Maximum runout:

0.12 mm (0.00472 in.)

If the runout is greater than the maximum value, replace the companion flange.

HINT
For reassembly purposes, record the result before disassembly.

(c) Perform the horizontal runout inspection.

(1) Set a dial indicator at a right angle to the surface of the companion flange as shown in the illustration.

(2) Measure the lateral runout of the companion flange.

Maximum runout:

0.08 mm (0.00314 in.)

If the runout is greater than the maximum value, replace the companion flange.

HINT
For reassembly purposes, record the result before disassembly.

4. REMOVE FRONT DIFFERENTIAL BREATHER PLUG

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

5. REMOVE FRONT DIFFERENTIAL CASE OIL SEAL

(a) Using SST, remove the oil seal LH from the differential carrier.

SST : 09308-00010

(b) Using SST, remove the oil seal RH from the differential carrier.

SST : 09308-00010

6. REMOVE FRONT DIFFERENTIAL CARRIER RETAINER SUB-ASSEMBLY

(a) Loosen the 11 bolts.

(b) Remove the differential carrier from the overhaul attachment.

(d) Insert the blade of an oil pan seal cutter between the differential carrier and differential carrier retainer. Cut through the applied seal packing.

NOTICE:
Do not damage the installation surface of the differential carrier.

(e) Using a brass bar and hammer, lightly tap the retainer to remove it from the differential carrier.

7. REMOVE NO. 1 FRONT DIFFERENTIAL CASE SUB-ASSEMBLY

(a) Remove the differential case from the differential carrier.

NOTICE:
Do not damage the differential case bearing and ring gear.

8. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

(a) Uniformly apply a light coat of Prussian blue on both sides of 4 teeth on the differential ring gear.

(b) Install the differential case to the differential carrier.

Torque : 58 Nm (591 kgf-cm, 43 ft-lbf)

(d) Rotate the companion flange several times in the forward and backward rotation directions.

(e) Remove the 11 bolts and retainer.

(f) Remove the differential case from the differential carrier.

(g) Inspect the tooth contact pattern.

HINT
For reassembly purposes, record the result before disassembly.

9. FIX DIFFERENTIAL CARRIER

(a) Fix the differential carrier to the overhaul stand's.

10. REMOVE FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

(a) Remove the 2 bolts and differential breather plug oil deflector.

11. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT

(a) Using SST and a hammer, unstake the staked part of the drive pinion companion flange nut.

SST : 09930-00010

NOTICE:
* Be sure to use SST with the tapered surface facing the shaft.
* Do not grind the tip of 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 companion flange nut.

SST : 09213-58013

SST : 09229-55010

SST : 09330-00021

NOTICE:
Perform the removal while supporting the overhaul attachment.

12. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY

(a) Using SST, remove the companion flange from the differential carrier.

SST : 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03020

HINT
Before using SST center bolt, apply hypoid gear oil to its threads and tip.

13. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR

(a) Using SST and a press, press out the dust deflector from the companion flange.

SST : 09950-00020

SST : 09950-60010

09951-00430

SST : 09950-70010

09951-07100

NOTICE:
* Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the dust deflector.
* Do not drop the companion flange.

14. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL

(a) Using a 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 from the differential carrier.

16. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING INNER RACE

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

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

NOTICE:
Do not drop the drive pinion.

(d) Remove the bearing inner race from the differential carrier.

(e) Install the differential carrier to the overhaul attachment as it was installed previously.

(f) Install the differential carrier together with overhaul attachment to the engine stand.

17. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Remove the bearing spacer from the drive pinion.

18. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING INNER RACE

(a) Using SST and a press, remove the front tapered roller bearing inner race from the drive pinion.

SST : 09950-00020

NOTICE:
Do not drop the drive pinion.

HINT
Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the front tapered roller bearing inner race.

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

19. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING OUTER RACE

(a) Using SST, remove the bearing outer race from the differential carrier.

SST : 09387-00041

09387-02020

20. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING OUTER RACE

(a) Using SST and a hammer, tap out the bearing outer race and adjusting shim from the differential carrier.

SST : 09950-70010

09951-07150

SST : 09950-60010

09951-00610

09951-00650

09952-06010

HINT
For reassembly purposes, measure the thickness of the adjusting shim, and record the result.

21. REMOVE FRONT DIFFERENTIAL CASE BEARING OUTER RACE LH

(a) Using SST and a press, press out the bearing outer race and case washer from the differential carrier.

SST : 09950-60010

09951-00640

09952-06010

SST : 09950-60020

09951-00680

SST : 09950-70010

09951-07100

22. REMOVE FRONT DIFFERENTIAL CASE BEARING OUTER RACE RH

(a) Using SST and a press, press out the bearing outer race and case washer from the differential carrier.

SST : 09950-60010

09951-00500

SST : 09950-70010

09951-07100

09951-00330

09952-06010

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.

(d) Remove the differential case from the vise.

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

HINT
Place a cloth on the tooth side of the ring gear to prevent damage.