Final Drive: Disassembly

NOTE: The differential is serviced as an assembly. Differential service is limited to bearing cups and cones. Any other differential component failure must be remedied by differential assembly and transfer shaft replacement.

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: Identifying Differential Cover Bolts
Courtesy of DAIMLERCHRYSLER CORP.

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

Fig 3: Identifying Differential Retainer Bolts
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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.
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 5) (Fig 6) (Fig 7).

Fig 5: Positioning Button And Collets Onto Differential And Bearing (Ring Gear Side)
Courtesy of DAIMLERCHRYSLER CORP.

Fig 6: Positioning Tool 5048 Over Button And Collets At Differential Bearing (Ring Gear Side)
Courtesy of DAIMLERCHRYSLER CORP.

Fig 7: Removing Differential Bearing Cone (Ring Gear Side)
Courtesy of DAIMLERCHRYSLER CORP.
Using Miller Special Tool L-4518, remove the differential bearing race from the extension housing.
Using Miller Special Tool 6062A, remove the differential bearing race from the bearing retainer (Fig 8) (Fig 9).

Fig 8: Positioning Bearing Cup Removing Tool In Retainer
Courtesy of DAIMLERCHRYSLER CORP.

Fig 9: Removing Bearing Cup
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Remove ring gear-to-differential case bolts and floating pinion shaft retainers (Fig 10).

Fig 10: Identifying Ring Gear-To-Case Bolts
Courtesy of DAIMLERCHRYSLER CORP.
Separate ring gear from differential case (Fig 11).

Fig 11: Locating Ring Gear
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Separate differential cover from case using suitable screwdrivers at position shown in (Fig 12).

Fig 12: Identifying Separating Differential Support With Screwdrivers
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Lift support from case (Fig 13).

Fig 13: Lifting Support From Case
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Remove side gear thrust washer (Fig 14).

Fig 14: Removing Side Gear Thrust Washer
Courtesy of DAIMLERCHRYSLER CORP.
Remove side gear (Fig 15).

Fig 15: Identifying Side Gear
Courtesy of DAIMLERCHRYSLER CORP.
Remove pinion shaft (Fig 16).

Fig 16: Identifying Pinion Shaft
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Remove pinion gears and tabbed washers (Fig 17).

Fig 17: Removing Pinion Gear
Courtesy of DAIMLERCHRYSLER CORP.
Remove differential side gear (Fig 18).

Fig 18: Removing Differential Side Gear
Courtesy of DAIMLERCHRYSLER CORP.
Remove side gear thrust washer (Fig 19).

Fig 19: Removing Side Gear Thrust Washer
Courtesy of DAIMLERCHRYSLER CORP.
Inspect all components for excessive wear.