Drive Axles: Overhaul: Disassembly

Mount carrier in a suitable repair stand. Attach a dial indicator to carrier (with button of indicator contacting back face of ring gear) and check ring gear deflection. Maximum allowable deflection is 0.004" (0.1 mm); replace ring and pinion if above specification. Punch identification marks on side bearing supports of carrier, differential bearing caps, and side bearing adjusters. Remove adjuster lock plates, loosen bearing cap attaching nuts or bolts, and slightly back off adjusters to relieve preload.
Remove bearing caps and adjusters, then withdraw differential assembly from carrier, making sure side bearing races remain with their respective bearings. If necessary for replacement, use a suitable puller and remove side bearings from gear case. Straighten lock tabs, remove ring gear attaching bolts, and separate ring gear from gear case.
On all models, except RX-4 and Cosmo manual transmission models, drive out differential pinion shaft lock pin with a punch and remove pinion shaft. Rotate pinion gears 90° and remove gears, thrust washer, thrust block (if equipped), and differential side gears. On RX-4 and Cosmo models, remove bolts joining differential case halves and separate case. Remove side gears, thrust washers, pinion gears, and spider.
On all models, remove pinion nut and pinion flange. Remove drive pinion and rear bearing assembly, adjusting shims (if equipped), spacer, and bearing collar (if used).
NOTE: It may be necessary to tap end of pinion with a soft hammer to remove from carrier.

Remove front oil seal and withdraw front pinion bearing. Using a press, remove rear bearing from drive pinion, then lift off pinion adjusting shim. If necessary for replacement, use a drift punch and remove pinion bearing races from carrier.