Front

Front Differential Carrier (2 Of 2):

1. Replace the companion flange dust deflector, if necessary by performing the following functions.





a. Using the 09950-00020 SST and a press, remove the dust deflector.





b. Using the 09636 - 20010 SST and a press, install a new dust deflector.

2. Replace the intermediate shaft No.2, if necessary by performing the following functions.
a. If the vehicle came w/ Automatic Differential Dissengagement (ADD), remove the clutch hub, doing the following.





1. Using a snap ring expander, remove the snap ring.
2. Remove the clutch hub from the intermediate shaft No.2.





b. Remove the oil seal by using the 09308-00010 Special Service Tool (SST), remove the oil seal from the differential tube.
c. Remove the intermediate shaft No.2
1. Using needle nose pliers, remove the snap ring.
2. Remove the shaft from the differential tube.
d. Remove the intermediate shaft No.2 bearing.
1. Using a snap ring expander, remove the snap ring.





2. Using the 09950-00020 SST, a brass bar and press, remove the bearing.

e. Install a new intermediate shaft No.2 bearing.





1. Using the 09309 - 37010 SST and a press, install a new bearing.
2. Using a snap ring expander, install the snap ring.

f. Install the intermediate shaft No.2
1. Install the shaft into the differential tube.
2. Using needle nose pliers, install the snap ring.

g. Install a new oil seal.





1. Using the 09223-15020 SST and a plastic hammer, install a new oil seal. The oil seal drive in depth should be 5.5 mm (0.217 inch).
2. Coat the oil seal lip with MP grease.

h. If the vehicle came w/ A.D.D., install the clutch hub, doing the following.





1. Install the clutch hub to the intermediate shaft No.2.
2. Using snap ring pliers, install the snap ring.

3. Replace the A.D.D. actuator, if necessary by performing these procedures.
a. Remove the A.D.D. switch.
b. Remove the sleeve fork pin.
1. Using a hexagon wrench, remove the screw plug.





2. Using a pin punch and hammer, remove the pin through the hole of clutch case cover.

c. Separate A.D.D. actuator from clutch case cover and remove the sleeve fork.
1. Using a hexagon wrench, remove the screw plug.
2. Remove the spring seat, spring and steel ball.
3. Remove the two bolts and actuator from the clutch case cover.
4. Separate the actuator from the clutch case cover and remove the sleeve fork.
5. Remove the Wring from the actuator.

d. Install the sleeve fork and A.D.D. actuator into the clutch case cover.





1. Install a new O-ring to the actuator.
2. Coat the Wring with MP grease.
3. Place the sleeve fork and install the actuator to the clutch case cover.
4. Tighten the two bolts to 21 Nm (15 ft. lbs.).
5. Install the steel ball, spring and spring seat.
6. Coat the threads of screw plug with Part No.08826 00090, THREE BOND 1281 or equivalent FIPG.
7. Using a hexagon wrench, install the screw plug, tightening the screw to 13 Nm (9 ft. lbs.).

e. Install the sleeve fork pin.
1. Using a pin punch and hammer, install the pin through the hole of clutch case cover.
2. Coat the threads of screw plug with Part No.0882-00090, THREE BOND 1281 or equivalent FIPG.
3. Using a hexagon wrench, install the screw plug, tightening it to 20 Nm (14 ft. lbs.).

f. Install a new gasket and the A.D.D. switch, tightening it down to 40 Nm (30 ft. lbs.).