Disassembly

Differential Carrier:

DISASSEMBLY
1. W/ A.D.D.:
Remove A.D.D. actuator.
a. Remove the 4 bolts.





b. Using a hammer handle, remove the actuator.

2. Remove differential tube.

W/ A.D.D.:
a. Remove the 4 torx bolts. Torx socket E14 (Part No. 09044-00010 or locally manufactured tool)
b. Using a plastic hammer, tap on the differential tube to remove it.
c. Remove the sleeve.
d. Remove the O-ring from the differential tube.

W/O A.D.D.:
a. Remove the 4 bolts.
b. Using a plastic hammer, tap on the differential tube to remove it.

3. W/ A.D.D.: Remove clutch case.
a. Remove the 2 torx bolts. Torx socket E14 (Part No.09044 - 00010 or locally manufactured tool)

b. Using a plastic hammer, tap on the clutch case to remove it.





4. Remove side oil seal. Using SST 09308-00010, remove the side oil seal.





5. W/ A.D.D.: Remove intermediate shaft No. 1. Using SST 09350-20015, 09950-40010 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04010, 09957-04010, 09958-04010), remove the intermediate shaft No. 1.





6. Remove companion flange.
a. Using a chisel and a hammer, unstake the nut.
b. Using SST 09330-00021 to hold the flange, remove the nut.





c. Using SST 09950-30010 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020), remove the companion flange.





7. Remove oil seal and oil slinger.
a. Using SST 09308-10010, remove the oil seal.
b. Remove the oil slinger.





8. Remove rear bearing and bearing spacer.
a. Using SST 09556-22010, remove the rear bearing from the drive pinion.
b. Remove the bearing spacer.





9. Remove side bearing retainer. Remove the 10 bolts and tap out the retainer with a plastic hammer.
10. Remove differential case assembly.
11. Remove drive pinion from differential carrier.





12. Remove drive pinion front bearing. Using SST 09950-00020 and a press, remove the bearing and washer from the drive pinion.

HINT: If the drive pinion or ring gear are damaged replace them as a set.





13. Remove drive pinion bearing outer races.
a. Using a brass bar and a hammer, remove the front bearing outer race.





b. Using SST 09502-12010, 09612-65014 (09612-01020, 09612-01050), remove the rear bearing outer race.

14. Remove side bearing outer races.

HINT:
^ Measure the plate washer and note the thickness.
^ Tag the bearing outer races to show the location for reassembly.





a. Using SST 09950-60010 (09951-00540), 09550-70010 (09951-01500) and a press, remove the plate washer and outer race from the bearing retainer.





b. Using SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) and a press, remove the plate washer and outer race from the differential carrier.

15. Remove ring gear.
a. Place matchmarks on the ring gear and differential case.





b. Using a screwdriver, unstake the lock plates.
c. Remove the 10 bolts and 5 lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.





16. Remove side bearings. Using SST 09950-40010 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04060, 09957-04010, 09958-04010), 09950-60010 (09951-00480), remove the side bearings from the differential case.

HINT: Fix the claws of SST to the notch in the differential case.





17. Disassemble differential case assembly.
a. Using a pin punch and a hammer, remove the straight pin.
b. Remove these parts from the differential case:
^ Pinion shaft.
^ 2 pinion gears.
^ 2 pinion gear thrust washers.
^ 2 side gears.
^ 2 side gear thrust washers.





18. W/ A.D.D.: Remove bearing. Using a brass bar and a hammer, remove the 2 bearings.