Front Differential Disassembly

Reference: FRONT DIFFERENTIAL DISMOUNTING AND REMOUNTING: FRONT 

1. Remove front drive shaft (1) from front drive shaft case (2) by using plastic hammer.
   Fig 1: Identifying Front Drive Shaft & Front Drive Shaft Case

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2. Remove axle lock actuator motor (1) and front drive shaft case (2) from differential housing (3) by removing bolts (4).
   Fig 2: Identifying Axle Lock Actuator Motor, Front Drive Shaft Case, Differential Housing & Bolts

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3. Remove front mounting bracket R (1) from differential housing (2) by removing bolts (3).
   Fig 3: Identifying Front Mounting Bracket R, Differential Housing & Bolts

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4. Remove 8 bolts (1, 2) and differential carrier cover for differential carrier.
   NOTE: Loosen 8 mm thread diameter bolts (2) first, and then loosen 12 mm thread diameter bolts (1).
   Fig 4: Identifying Differential Carrier Bolts

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5. Remove axle lock actuator mounting bolts (1).
6. Take off differential side bearing outer races (2) and bevel gear with differential case (3).
   Fig 5: Identifying Differential Side Bearing Outer Races, Bolts And Bevel Gear With Differential Case

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7. Hold universal joint flange with special tool, and then remove flange nut by using socket wrench (2) and power wrench (3).

   Special Tool 

   (B): 09922-66021 

   Fig 6: Identifying Bolt, Socket Wrench And Power Wrench

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8. Make mating marks (1) on pinion and universal joint flange.
   CAUTION: Do not make mating mark on the coupling surface of the flange.
9. Remove universal joint flange from pinion using special tool.

   Special Tool 

   (C): 09913-65135 

   Fig 7: Identifying Mating Marks & Special Tool

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10. Remove pinion with front bearing and bearing pinion spacer from differential carrier. If it is hard to remove, screw an used nut into pinion and hammer on the nut with a plastic hammer but never directly on pinion.
    Fig 8: Removing Pinion With Front Bearing And Bearing Pinion Spacer

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11. Remove oil seal and take out rear bearing.
12. Using special tool, pull out differential side bearings.

    Special Tool 

    (D): 09913-85230 

    Fig 9: Identifying Differential Side Bearings Special Tool

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13. With aluminum plates (3) placed on vise first, grip differential case with it and remove bevel gear (2) by removing bolts (1).
    CAUTION: Use care not to hold axle lock clutch part with vise. Be sure to hold differential left case.
    Fig 10: Identifying Bolts, Bevel Gear & Aluminum Plates

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14. Separate differential case assembly by removing 2 screws (2) and take out free axle hub, differential gears and shims from differential left case (1).
    Fig 11: Identifying Axle Lock Clutch, Differential Left Case And Screw

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15. Remove front bearing (2) from pinion (1) by using bearing puller (3) and hydraulic press.
    Fig 12: Identifying Front Bearing, Pinion & Puller

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16. Drive out pinion bearing outer races in differential carrier by hammering metal stick applied to them.
    Fig 13: Applying Metal Stick To Bearing Outer Races

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