Replacement

1. Replace companion flange dust deflector, if necessary.
a. Using Special Service Tool (SST) 09950-00020 or equivalent and a press, remove the dust deflector.





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

2. Replace side gear shaft, if necessary.
a. Remove clutch hub.





1) Using a snap ring expander, remove the snap ring.
2) Remove the clutch hub from the side gear shaft.
b. Remove left hand side gear shaft from tube.
1) Remove the three bearing retainer bolts.
2) Remove the side gear shaft from the tube.
c. Replace left hand side gear shaft bearing dust cover.
1) Using a snap ring expander, remove the snap ring.





2) Using Special Service Tool (SST) 09950-00020 or equivalent and a press, remove the bearing.
3) Remove the bearing retainer.
4) Using a screwdriver and hammer, remove the dust cover.





5) Using SST 09316-20011 or equivalent and a press, install a new dust cover.
6) Install the bearing retainer.





7) Using SST 09316-60011 (09316-00041) or equivalent and a press, install a new bearing.
8) Using a snap ring expander, install a new snap ring.
d. Replace left hand side oil seal.





1) Using SST 09308-00010 or equivalent, remove the side oil seal.





2) With the oil seal lip facing upward, use a press and a plate to press in a new oil seal until its end is flush with the surface of the tube.





3) Using SST 09554-14010 or equivalent and a press, install the oil seal.
Oil seal drive in depth: 2.5 mm (0.098 inch).
4) Coat the lip of oil seed with Multipurpose (MP) grease.
e Install left hand side gear shaft to tube.





1) Install the side gear shaft into the tube.
2) Tighten the three bearing retainer bolts.
f. Install clutch hub.
1) Install the clutch hub to the shaft.
2) Using a snap ring expander, install a new snap ring.
g. Replace right hand side gear shaft dust cover.
1) Using a screwdriver and hammer, remove the dust cover.





2) Using SST 09710-30055 or equivalent and a press, install a new dust cover.
3. Replace A.D.D. actuator, if necessary.
a. Remove the Automatic Disconnecting Differential (A.D.D.) indicator switch.
b. Remove 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 actuator from clutch case cover and remove 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 sleeve fork and actuator into the clutch case cover.
1) Install a new O-ring to the actuator.
2) Coat the O-ring with Multipurpose (MP) grease.
3) Place the sleeve fork and install the actuator to the clutch case cover.
4) Torque 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: 20 Nm (14 ft. lbs.)
e. Install sleeve fork pin.
1) Using a pin punch and hammer, install the pin through the hole of clutch case cover.
2) Using a hexagon wrench, install the screw plug.
Torque: 20 Nm (14 ft. lbs.)