Disassembly

Front Differential Carrier - 4 WD:

1. Remove Automatic Disconnecting Differential (A.D.D.) Actuator, as follows:





a. Remove the four bolts.
b. Using a hammer handle, remove the actuator.

2. Remove differential carrier cover. Remove the eight bolts and tap out the cover with a plastic hammer.





3. Check side gear backlash. Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the differential case. If the backlash is out of specification, install the correct thrust washers.

Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch).

4. Remove left hand side gear shaft with the tube, as follows:





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

5. Remove clutch case, as follows:
a. Using a (E14) torx socket, remove the two torx bolts.





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





6. Remove right hand side gear shaft. Using Special Service Tool (SST) 09910 - 00015 (09911 - 00011, 09912 - 00010, 09914 - 00011) or equivalent, remove the right hand side gear shaft.





7. Remove right hand side shaft oil seal. Using SST 09308 - 00010 or equivalent, remove the right side gear shaft oil seal.





8. Remove intermediate shaft. Using SST 09350 - 20015 (09369 - 20040), 09950 - 40010 or equivalent, remove the intermediate shaft.





9. Check ring gear runout. Using a dial indicator, measure the ring gear runout. If the runout is greater than the maximum, replace the ring gear and drive pinion as a set.

Maximum runout:0.07 mm (0.0028 inch).

10. Check the ring gear backlash, as follows:
a. Fix the dial indicator on the tooth surface at a 90° angle.





b. Using a dial indicator, with holding the drive pinion flange and measure the ring gear backlash. If the backlash is not within the specification, adjust the ring gear backlash.

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0070 inch).

NOTE: Measure from three or more places on the circumference of the ring gear.

11. Inspect tooth contact between ring gear drive pinion.
12. Remove companion flange, as follows:
a. Using a chisel and hammer, unstake the nut.





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





c. Using SST 09950 - 30010 or equivalent, remove the companion flange.

13. Remove oil seal and oil slinger, as follows:





a. Using SST 09308 - 10010 or equivalent, remove the oil seal from the differential carrier.
b. Remove the oil slinger.

14. Remove rear bearing and bearing spacer, as follows:





a. Using SST 09556 - 30010 or equivalent, remove the rear bearing from the drive pinion.
b. Remove the bearing spacer.

15. Remove differential case assembly, as follows:
a. Place matchmarks on the bearing cap and differential carrier.





b. Remove the four bolts and two bearing caps.





c. Using SST 09504 - 22011 or equivalent and hammer, remove the two side bearing plate washers.

NOTE: Measure the plate washer and note the thickness.

d. Remove the differential case with the bearing outer races from the differential carrier.

NOTE: Tag the bearing outer races to show the location for reassembly.

16. Remove drive pinion from differential carrier.





17. Using SST 09950 - 00020 or equivalent and a press, remove the drive pinion bearing from the drive pinion.

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





18. Remove drive pinion bearing outer races. Using a brass bar and hammer, remove the two drive pinion bearing outer races from the differential carrier.
19. Remove ring gear, as follows:
a. Place matchmarks on the ring gear and differential case.





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





20. Remove side bearings. Using SST 09950 - 40010, 09950 - 60010 (09951 - 00480) or equivalents, remove the two side bearings from the differential case.

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

21. Disassemble differential case assembly, as follows:
a. Using a pin punch and hammer, remove the straight pin.
b. Remove these parts from the differential case:
- Pinion shaft.
- Two pinion gears.
- Two pinion gear thrust washers.
- Two side gears.
- Two sided gear thrust washers.





c. Using a brass bar and hammer, remove the two bearings.