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Drive Axles: Overhaul: Disassembly

  1. Remove bolts and lock washers joining front and rear differential housings. Remove front housing and differential carrier from rear housing. Place differential housing in a vice and mark bearing caps for reassembly. Remove bearing caps.
  2. Install suitable differential spreader (S101 & -1) to differential housing. Spread housing and pry out differential carrier.
    CAUTION: Do not exceed 0.008" (0.20 mm) spread of housing or damage to case may occur.

    Using suitable tools (18G47C & -BD), press carrier bearings from carrier assembly.

  3. Mark ring gear and carrier for proper reassembly. Remove ring gear and drive out cross shaft locking pin. Push out pinion cross shaft and rotate pinion gears 90° to carrier opening. Remove pinion gears and side gears with their thrust washers.
  4. Remove cotter pin from pinion shaft. Using suitable flange holder (RG421 or S337), remove pinion shaft nut and flange. Press out pinion shaft and remove shims and spacer. Using suitable tools (S4221A & -17), press bearing from pinion shaft. With a drift, drive out bearing races and oil seal from pinion housing.
    NOTE: Ring and pinion gears are replaced as a matched set only. Numbers etched on each gear must be the same.
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