FRONT DIFFERENTIAL CARRIER ASSEMBLY > DISASSEMBLY

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

   SST

   09564-32011  
   

   Backlash:

   0.11 to 0.21 mm (0.0043 to 0.0083)
   

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

      HINT:

      Perform the measurements at 3 or more positions around the side bearing preload.

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

   Maximum runout:

   
   

   Runout	Maximum
   Vertical runout	0.10 mm (0.0039 in.)
   Lateral runout	0.10 mm (0.0039 in.)

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

1. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
   

   Torque:

   Preload (at start of torque):

   0.49 to 0.78 N*m{ 5 to 8 kgf*cm , 4.3 to 6.9 in.*lbf }

1. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
   

   Torque:

   Total preload (at start of torque):

   0.22 to 0.85 N*m{ 6 to 9 kgf*cm , 1.9 to 7.7 in.*lbf }

   1. If necessary, disassemble and inspect the differential.
      

1. Remove the 4 bolts.
   

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

1. Remove the 4 bolts.
   

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

1. Using SST, tap out the oil seal.
   

   SST

   09308-00010  
   

1. 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)
   

2. Remove the snap ring from the inter shaft.
   

1. Using a screwdriver, pry out the bearing retainer deflector.
   

   HINT:

   Tape the screwdriver tip before use.

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

   SST

   09330-00021  
   

2. Using SST to hold the companion flange in place, remove the nut.
   

   SST

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

1. Using SST, remove the companion flange.
   

   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.

1. Using SST and a press, press out the dust deflector.
   

   SST

   09950-00020  
   09950-60010   (09951-00510)
   09950-70010   (09951-07150)
   

   NOTICE:

   Do not drop the companion flange.

1. Using SST, remove the oil seal from the differential carrier.
   

   SST

   09308-10010  
   

1. Remove the oil slinger from the drive pinion.
   

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

   SST

   09556-22010  
   

2. Remove the bearing spacer.
   

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

1. Using SST and a press, press out the roller bearing (inner) 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.

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

1. Using SST, remove the roller bearing (outer).
   

   SST

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

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

HINT:

1. Measure the thickness of the case washer.
   

1. Tag the bearing outer races to show the location for reassembly.
   

1. Using SST and a press, press out the case bearing (outer race) 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.
      

2. Using SST and a press, press out the case bearing (outer race) 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.
      

1. Place matchmarks on the ring gear and differential case.
   

2. Remove the 10 ring gear set bolts.
   

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

HINT:

The differential case and case bearings should only be removed when replacement is necessary.

1. 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:

   Fix the claws of SST to the notch in the differential case assembly.

1. Using a chisel and hammer, unstake the differential case.
   

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

3. 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)
      

1. 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.
      

1. Check that the differential case is not damaged.
   

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

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

1. Using a snap ring expander, remove the snap ring.
   

2. Remove the differential clutch hub.
   

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

   SST

   09308-00010  
   

1. Using a snap ring expander, remove the snap ring.
   

2. Remove the shaft from the differential tube.
   

1. Using a snap ring expander, remove the snap ring.
   

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

   SST

   09950-00020  
   

   NOTICE:

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

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

   1. Replace parts as necessary.
      

2. Check that the clutch sleeve slides smoothly on the clutch hub.
   Replace parts as necessary.
   

1. Check that there is no wear or damage on the clutch hub and side gear inter shaft.
   

   1. Replace parts as necessary.
      

2. Check that clutch sleeve slides smoothly on the side gear inter shaft.
   Replace parts as necessary.
   

1. 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 greater than the maximum, replace the fork or clutch sleeve.