Disassembly and Assembly: Disassembly

Differential Assembly

1. Drain the differential gear oil if necessary.
2. Remove the differential side shaft and differential side flange using suitable tool.
   Fig 1: Removing Differential Side Shaft And Side Flange Using Tool

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3. Remove the extension tube and O-ring from the gear carrier.
   CAUTION: Do not reuse O-ring.
   Fig 2: O-Ring, Extension Tube And Gear Carrier With Torque Specifications

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4. Place a small hole in the side oil seal case using suitable tool.
   Fig 3: Identifying Side Oil Case Small Hole

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5. Remove the side oil seal using Tool as shown.

   Tool number: - SP8P 

   Fig 4: Removing Side Oil Seal Using Tool

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6. Remove the carrier cover bolts and separate the carrier cover from the gear carrier using Tool.

   Tool number: KV10111100 (J-37228) 

   Fig 5: Separating Carrier Cover From Gear Carrier Using Tool

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   CAUTION:

   • Do not damage the mating surface.
   • Do not insert flat-bladed screwdriver, this will damage the mating surface.
7. For proper reinstallation, paint matching marks on one side of the side bearing cap and gear carrier.
   CAUTION:

   • For matching marks, use paint. Do not damage side bearing cap or gear carrier.
   • Side bearing caps are line-board during manufacture. The matching marks are used to reinstall them in their original positions.
     Fig 6: Identifying Matching Mark On Bearing Cap And Gear Carrier

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8. Remove the side bearing caps.
   Fig 7: Removing Side Bearing Caps

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9. Remove the side bearing adjuster.
   Fig 8: Removing Side Bearing Adjuster

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10. Lift the differential case assembly out of the gear carrier.
    CAUTION: Keep side bearing outer races together with side bearing inner races. Do not mix them up.
    Fig 9: Removing Differential Case Assembly From Gear Carrier

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11. Remove side bearing inner race using Tools as shown.

    Tool number (A): ST33081000 (-) 

    (B): ST30021000 (-) 

    Fig 10: Removing Side Bearing Inner Race Using Tools

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    CAUTION:

    • Do not remove side bearing inner race unless it is being replaced.
    • Place copper plates between the vise and the side bearing inner race and drive gear to prevent damage.
    • Engage puller jaws in groove to prevent damage to bearing.
    • Keep side bearing outer races together with side bearing inner races. Do not mix them up.
      Fig 11: Identifying Left And Right Side Parts Label

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12. For proper reinstallation, paint matching marks on the differential case and drive gear.
    CAUTION: Use paint for matching marks. Do not damage differential case or drive gear.
13. Remove the drive gear bolts.
14. Tap the drive gear off the differential case using suitable tool.
    CAUTION: Tap evenly all around to keep drive gear from bending.
    Fig 12: Locating Drive Gear Bolts

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15. Remove the lock pin of the pinion mate shaft from the drive gear side using suitable tool.
    Fig 13: Removing Pinion Mate Shaft Lock Pin Using Tool

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16. Remove the pinion mate shaft.
    Fig 14: Removing Pinion Mate Shaft

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17. Turn the pinion mate gear, then remove the pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from the differential case.
    Fig 15: Turning Pinion Mate Gear

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Drive Pinion Assembly

1. Remove the differential assembly.
2. Remove the drive pinion lock nut using suitable tool.
3. Put matching marks on the companion flange and drive pinion using paint.
   CAUTION: Use paint to make the matching marks. Do not damage the companion flange or drive pinion.
   Fig 16: Removing Drive Pinion Lock Nut Using Tool

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4. Remove the companion flange using suitable tool.
   Fig 17: Removing Companion Flange Using Suitable Tool

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5. Press the drive pinion assembly (with rear inner bearing race and collapsible spacer) out of the gear carrier.
   CAUTION: Do not drop drive pinion assembly.
   Fig 18: Pressing Drive Pinion Assembly Out Of Gear Carrier

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6. Remove the drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool.

   Tool number: ST30021000 (-) 

   Fig 19: Removing Drive Pinion Rear Bearing Inner Race And Height Adjusting Washer Using Tool

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7. Place a small hole in the front oil seal case using suitable tool.
   Fig 20: Identifying Side Oil Case Small Hole

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8. Remove the front oil seal using Tool as shown.

   Tool number: - SP8P 

   Fig 21: Removing Front Oil Seal Using Tool

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9. Remove the drive pinion front bearing inner race.
10. Remove the drive pinion front bearing outer race using Tool as shown. Locate the driver on the back edge of the drive pinion front bearing outer race, then drive the drive pinion front bearing outer race out.

    Tool number (A): - C-4171 

    (B): - D-103 

    Fig 22: Removing Drive Pinion Front Bearing Outer Race Using Tool

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    CAUTION: Do not damage gear carrier.
11. Remove the drive pinion rear bearing outer race using Tool as shown. Locate the driver on the back edge of the drive pinion rear bearing outer race, then drive the drive pinion rear bearing outer race out.

    Tool number (A): - C-4171 

    (B): - C-4307 

    Fig 23: Removing Drive Pinion Rear Bearing Outer Race Using Tool

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    CAUTION: Do not damage gear carrier.