Final Drive: Disassembly

NOTE: The differential is serviced as an assembly. The only parts that are serviceable within the differential are the differential bearing cups and cones. If any other part fails within the differential, you must replace the differential assembly along with the transfer shaft.

The transfer shaft should be removed for differential repair and bearing turning torque checking.

Remove the differential cover and bolts (Fig 1) (Fig 2).

Fig 1: Removing Differential Cover Bolts
Courtesy of DAIMLERCHRYSLER CORP.

Fig 2: Removing Remove Differential Cover
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Remove the differential bearing retainer and bolts (Fig 3) (Fig 4).

Fig 3: Removing Differential Retainer Bolts
Courtesy of DAIMLERCHRYSLER CORP.

Fig 4: Removing Bearing Retainer
Courtesy of DAIMLERCHRYSLER CORP.
Using a plastic hammer, remove extension housing/adapter plate on the right side of the transaxle.
WARNING: Hold onto differential assembly to prevent it from rolling out of housing.
Remove differential assembly.
Set up dial indicator set C-3339 and tool C-4996 as shown in (Fig 5) (Fig 6) to measure side gear end play. Side gear end play must be within 0.001-0.013 in.

Fig 5: Checking Side Gear End Play (Extension Housing Side)
Courtesy of DAIMLERCHRYSLER CORP.

Fig 6: Checking Side Gear End Play (Ring Gear Side)
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Use Miller Special Tool 5048, 5048-3 Collets, and L-4539-2 Button to remove the differential bearing cone on the extension housing side.
Use Miller Special Tool 5048, 5048-4 Collets, and L-4539-2 Button to remove the differential bearing cone on the bearing retainer side (Fig 7) (Fig 8) (Fig 9).

Fig 7: Removing Differential Bearing Cone On Bearing Retainer Side (1 Of 2)
Courtesy of DAIMLERCHRYSLER CORP.

Fig 8: Removing Differential Bearing Cone On Bearing Retainer Side (2 Of 2)
Courtesy of DAIMLERCHRYSLER CORP.
Using Miller Special Tool L-4518, remove the differential bearing race from the extension housing/adapter plate.

Fig 9: Removing Differential Bearing Cone (Ring Gear Side)
Courtesy of DAIMLERCHRYSLER CORP.
Using Miller Special Tool 6062A, remove the differential bearing race from the bearing retainer (Fig 10) (Fig 11).