Differential Assembly: Disassembly

Drain differential. Remove differential assembly. See DIFFERENTIAL ASSEMBLY under REMOVAL & INSTALLATION. Install differential carrier to an overhaul stand. Using a slide hammer, remove side gear shafts. Remove side gear shaft oil seals from differential case. Paint a match mark on differential carrier retainers. Remove 8 differential carrier retainer bolts. Using a puller, remove differential carrier retainers. See Fig 1.
Remove differential case from differential carrier while holding ring gear side upward. Remove "O" ring from differential carrier retainers. Using a press and adapter, remove outer races and adjusting plate washer from differential carrier retainers.
Unstake and remove drive pinion nut. Using a press, remove companion flange, drive pinion and rear bearing. Do not allow drive pinion to drop. Remove spacer from drive pinion. Remove oil seal, oil slinger and drive pinion front bearing. See Fig 1. Using a press, remove rear bearing from drive pinion.
If replacing drive pinion front bearing, remove outer bearing race and adjusting washer from differential carrier. Measure thickness of adjusting washer for reassembly. Remove snap ring from side gear shafts and discard.
Remove side bearings from differential case. See Figure. Paint match marks on ring gear and differential carrier. DO NOT use punch marks. Remove 10 ring gear bolts. Using a plastic hammer, separate the ring gear from differential case. Using a punch, remove the differential case straight pin. Remove pinion shaft, 2 differential pinions, 2 pinion thrust washers, 2 side gears and 2 side gear thrust washers. See Fig 1.
Using a press and an adapters, remove old dust deflector from companion flange and install a NEW dust deflector. Using a press and an adapters, remove old dust cover from side gear shafts and install NEW dust cover. Ensure dust cover fits tightly against side gear shaft flange.

Fig 1: Exploded View Of Differential Assembly