Disassembly

1. Check runout of companion flange.
Using a dial indicator, measure the runout of the companion flange vertical and lateral runout.
Maximum:
Vertical runout: 0.10 mm (0.0039 inch)
Lateral runout: 0.10 mm (0.0039 inch)





2. Measure drive pinion preload.
Using a torque wrench, measure the drive pinion preload using the backlash of the drive pinion and ring gear.
Preload (at starting): 0.6 - 1.0 Nm (5.2 - 8.7 inch lbs.)
If the runout is greater than the maximum, replace the companion flange.
3. Check total preload.
Using a torque wrench, measure the total preload.
Total preload (at starting): Drive pinion preload plus 0.4 - 0.6 Nm (3.5 - 5.2 inch lbs.)
If necessary, disassemble and inspect the differential.
4. Remove Automatic Disconnecting Differential (A.D.D.) Actuator.





a. Remove the four bolts.
b. Using a hammer handle, remove the actuator.
5. Remove differential carrier cover.
Remove the eight bolts and tap out the cover with a plastic hammer.





6. Check side gear backlash.
Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the differential case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch).
If the backlash is out of specification, install the correct thrust washers.
7. Remove left hand side gear shaft with the tube.





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.
8. Remove clutch case.
a. Using a (E14) torx socket, remove the two torx bolts.





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





9. 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.





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





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





12. Check ring gear runout.
Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.07 mm (0.0028 inch).
If the runout is greater than the maximum, replace the ring gear and drive pinion as a set.
13. Check the ring gear backlash.
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.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0070 inch).
If the backlash is not within the specification, adjust the ring gear backlash.

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

14. Inspect tooth contact between ring gear drive pinion.
15. Remove companion flange.
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.
16. Remove oil seal and oil slinger.





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





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

HINT: Measure the plate washer and note the thickness.

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

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

19. Remove drive pinion from differential carrier.





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

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





21. Remove drive pinion bearing outer races.
Using a brass bar and hammer, remove the two drive pinion bearing outer races from the differential carrier.
22. Remove ring gear.
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.





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

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

24. Disassemble differential case assembly.
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.