Disassembly

Front Differential Carrier (1 Of 2):

Front Differential Carrier (2 Of 2):

1. Check the runout of the companion flange by using a dial indicator. Measure the vertical and lateral runout of the companion flange. The maximum runout is 0.10 mm (0.0039 inch). If the runout is greater than the maximum, replace the companion flange.





2. Check the ring gear backlash. Using the 09564-32011 Special Service Tool (SST) and a dial indicator, measure the ring gear backlash. The backlash should be 0.10 - 0.18 mm (0.0039 - 0.0071 inch). If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.





3. Using a torque wrench, measure the drive pinion preload of backlash between the drive pinion and ring gear. The preload (at starting) should be 0.6 -1.0 Nm (5.2 - 8.7 inch lbs.).
4. Check the total preload by using a torque wrench and measureing the preload with the teeth of the drive pinion and ring gear in contact. The total preload (at starting) should be 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.). If necessary, disassemble and inspect the differential.
5. If the vehicle came with Automatic Differential Disengagement (ADD), remove the A.D.D. actuator performing the following.
a. Remove the four bolts.





b. Using a hammer handle, remove the actuator.

6. If the vehicle came with A.D.D., remove the differential tube, perform the following steps.





a. Using a (E14) torx socket , remove the four torx bolts.
b. Using a plastic hammer, remove the differential tube.
c. Remove the sleeve.
d. Remove the O-ring from the differential tube.

If the vehicle came w/o A.D.D., perform these steps.
a. Remove the four bolts.
b. Using a plastic hammer, remove the differential tube.

7. If the vehicle came with A.D.D.,remove the clutch case by doing the following.
a. Using a (E14) torx socket , remove the two torx bolts.
b. Using a plastic hammer, remove the clutch case.





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





9. If the vehicle came with A.D.D., Using the 09350-20015, 09950-0010 (09951 - 04010, 09952-04010, 09953 - 04020, 0995-04010, 09955-04010, 09957-04010, 09958-04010) SST, remove the intermediate shaft No.1.

10. Remove the companion flange by performing these functions.
a. Using a chisel and hammer, unstake the nut.





b. Using the 09330-00021 SST to hold the flange, remove the nut.





c. Using the 09950-30010 (09951-03010, 09953-03010, 0995-03010, 09955-03030, 0995-03020) SST, remove the companion flange.

11. Remove the oil seal and the oil slinger, doing the following.





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

12. Remove the rear bearing and the bearing spacer, doing the following.





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

13. Remove the side bearing retainer after removing the 10 bolts and tap out the retainer with a plastic hammer.
14. Remove the differential case assembly.
15. Remove the drive pinion from the differential carrier.





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

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

17. Remove drive pinion bearing outer races.





a. Using a brass bar and hammer, remove the front bearing outer race.





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

18. Remove the side bearing outer races, doing these steps.

NOTE:
- Measure the plate washer and note the thickness.

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





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





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

19. Remove the ring gear by performing these procedures.
a. Place matchmarks on the ring gear and differential case.
b. Using a screwdriver, unstake the five lock plates.
c. Remove the ten bolts and five lock plates.





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





20. Using the 0995-40010 (09951-4010, 09952-04010, 09953 - 04020, 09954 - 04010, 09954 - 04010, 09955-04060, 09957-4010, 09958 - 04010), 09950-60010 (09951-00480) SST, remove the two side bearings from the differential case.

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

21. Disassemble the differential case assembly, doing the following.





a. Using a pin punch and hammer, remove the straight pin.
b. Remove these parts from the differential case, the pinion shaft, the two pinion gears, two pinion gear thrust washers, two side gears and the two side gear thrust washers.





22. If the vehicle came w/ A.D.D., using a brass bar and hammer, remove the two bearings.