Front Differential Carrier Assembly Disassembly

Using SST and a dial indicator, measure the ring gear backlash.

SST

09564-33010

Backlash:

0.11 to 0.21 mm (0.00433 to 0.00826 in.)

1. If the backlash is not as specified, adjust the side bearing preload or perform repairs as necessary.
   

   HINT:

   Perform the measurement at 3 or more positions around the circumference of the ring gear.

Using a dial indicator, measure the runout of the companion flange vertically and laterally.

Maximum Runout:

Item	Specified Condition
Vertical runout	0.10 mm (0.00394 in.)
Lateral runout	0.10 mm (0.00394 in.)

1. If the runout is more than the maximum, replace the companion flange.
   

Remove the 4 bolts.

Using a hammer, pry out the actuator from the differential tube.

Remove the 4 bolts.

Using a plastic-faced hammer, tap out the differential tube.

Using SST, tap out the oil seal.

SST

09308-00010

Remove the differential clutch sleeve.

Remove the snap ring from the inter shaft.

Using SST, remove the inter shaft.

SST

09350-20015(09369-20040)
09950-40011(09951-04010,09952-04010,09953-04020,09954-04010,09955-04011,09957-04010,09958-04011)

Using a screwdriver, pry out the bearing retainer deflector.

HINT:

Tape the screwdriver tip before use.

Using SST and a hammer, loosen the staked part of the nut.

SST

09930-00010(09931-00010,09931-00020)

Using SST to hold the companion flange, remove the nut.

SST

09330-00021(09330-00030)

Using SST, remove the companion flange with dust deflector.

SST

09950-30012(09951-03010,09953-03010,09954-03010,09955-03030,09956-03020)

NOTICE:

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

Using SST, remove the oil seal.

SST

09308-10010

Remove the oil slinger from the drive pinion.

Using SST, remove the roller bearing (inner) from the drive pinion.

SST

09556-22010

Remove the 10 bolts and tap out the retainer with a plastic-faced hammer.

Remove the bearing spacer from the drive pinion.

Using SST and a press, press out the roller bearing (inner) and drive pinion plate washer from the drive pinion.

SST

09950-00020

NOTICE:

Do not drop the drive pinion.

HINT:

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

Using a brass bar and hammer, tap out the roller bearing (outer).

Using SST, remove the roller bearing (outer).

SST

09502-12010
09612-65014(09612-01020,09612-01050)

Using a brass bar and hammer, tap out the oil storage ring.

Using SST and a press, press out the case bearing (outer) and plate washer from the bearing retainer.

SST

09950-60020(09951-00680)
09950-70010(09951-07150)

1. If the bearing is damaged during removal, replace it.
   

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

SST

09950-60020(09951-00680)
09950-70010(09951-07150)

1. If the bearing is damaged during removal, replace it.
   

Place matchmarks on the ring gear and differential case.

Remove the 10 ring gear set bolts.

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

Using SST, remove the 2 case bearings (inner) from the differential case.

SST

09950-60010(09951-00480)
09950-40011(09951-04020,09952-04010,09953-04030,09954-04010,09955-04061,09953-04020,09958-04011)

HINT:

Attach the claws of SST to the notch in the differential case assembly to secure SST.

Using a chisel and hammer, unstake the differential case.

Using a pin punch and hammer, tap out the straight pin.

Remove the following parts from the differential case.

1. (1) Differential pinion gear (2 pieces)
   
2. (2) Differential pinion gear thrust washer (2 pieces)
   
3. (3) Differential pinion shaft
   
4. (4) Differential side gear (2 pieces)
   
5. (5) Differential side gear thrust washer (2 pieces)
   

Check that the differential pinion and differential side gear are not damaged.

1. If the differential pinion or differential side gear is damaged, replace the differential gear kit.
   

Check that the differential case is not damaged.

1. If the differential case is damaged, replace it.
   

Using a brass bar and hammer, tap out the 2 bearings.

Using a snap ring expander, remove the snap ring.

Remove the differential clutch hub.

Using SST, tap out the oil seal from the differential tube.

SST

09308-00010

Using a snap ring expander, remove the snap ring.

Remove the shaft from the differential tube.

Using a snap ring expander, remove the snap ring.

Using SST, a brass bar and a press, press out the shaft RH bearing.

SST

09950-00020

NOTICE:

1. Do not damage the bearing.
   
2. Do not drop the shaft.
   

Check that there is no wear or damage on the clutch hub and clutch sleeve.

1. If necessary, replace them.
   

Check that the clutch sleeve slides smoothly on the clutch hub.

Check that there is no wear or damage on the clutch sleeve and side gear inter shaft.
If necessary, replace clutch sleeve and side gear inter shaft.

Check that clutch sleeve slides smoothly on the side gear inter shaft.

Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve.

Maximum clearance:

0.35 mm (0.0138 in.)

1. If the clearance is more than the maximum, replace the fork or clutch sleeve.