Front

Front Differential Carrier (2 Of 2):

1. Replace the companion flange dust deflector, if necessary.





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





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

2. Replace the intermediate shaft No.2, if necessary.
a. w/ Automatic Disconnecting Differential (ADD):
Remove the clutch hub.





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

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





1) Using the SST 09309-37010 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 SST 09223-15020 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. w/ A.D.D.:
Install the clutch hub.





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.
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 O-ring 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 O-ring with MP grease.
3) Place the sleeve fork and install the actuator to the clutch case cover.
4) Tighten the two bolts.
Torque: 21 Nm (15 ft. lbs.).
5) Install the steel ball, spring and spring seat.
6) Coat the threads of screw plug with Formed In Place Gasket (FIPG)
FIPG: THREE BOND 1281 or equivalent.
7) Using a hexagon wrench, install the screw plug.
Torque: 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 FIPG.
FIPG:THREE BOND 1281 or equivalent.
3. Using a hexagon wrench, install the screw plug.
Torque: 20 Nm (14 ft. lbs.).
f. Install the A.D.D. switch.
Install a new gasket and the A.D.D. switch.
Torque: 40 Nm (30 ft. lbs.).