Disassembly

DISASSEMBLY

The transfer shaft should be removed for differential repair and bearing turning torque checking.

Fig. 210 Differential Cover Bolts:

Fig. 211 Remove Differential Cover:

1. Remove the differential cover and bolts (Fig. 210) (Fig. 211).

Fig. 212 Differential Retainer Bolts:

Fig. 213 Remove Bearing Retainer:

2. Remove the differential bearing retainer and bolts (Fig. 212) (Fig. 213).
3. 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.

4. Use Puller Set 5048, 5048-3 Collets, and L-4539-2 Button to remove the differential bearing cone on the extension housing side.

Fig. 214 Position Button and Collets Onto Differential and Bearing (Ring Gear Side):

Fig. 215 Position Puller Set 5048 Over Button and Collets at Differential Bearing (Ring Gear Side):

Fig. 216 Remove Differential Bearing Cone (Ring Gear Side):

5. Use Puller Set 5048, 5048-4 Collets, and L-4539-2 Button to remove the differential bearing cone on the bearing retainer side (Fig. 214) (Fig. 215) (Fig. 216).
6. Using Special Jaw Set L-4518, remove the differential bearing race from the extension housing.

Fig. 217 Position Bearing Cup Remover Tool in Retainer:

Fig. 218 Remove Bearing Cup:

7. Using Remover 6062A, remove the differential bearing race from the bearing retainer (Fig. 217) (Fig. 218).

Fig. 219 Ring Gear-to-Case Bolts:

8. Remove ring gear-to-differential case bolts and floating pinion shaft retainers (Fig. 219).

Fig. 220 Ring Gear Removal:

9. Separate ring gear from differential case (Fig. 220).

Fig. 221 Separating Differential Support with Screwdrivers:

10. Separate differential cover from case using suitable screwdrivers at position (Fig. 221)

Fig. 222 Differential Support Removal:

11. Lift support from case (Fig. 222).

Fig. 223 Side Gear Thrust Washer Removal:

12. Remove side gear thrust washer (Fig. 223).

Fig. 224 Side Gear Removal:

13. Remove side gear (Fig. 224).

Fig. 225 Pinion Shaft Removal:

14. Remove pinion shaft (Fig. 225).

Fig. 226 Pinion Gear and Washer Removal:

15. Remove pinion gears and tabbed washers (Fig. 226).

Fig. 227 Side Gear Removal:

16. Remove differential side gear (Fig. 227).

Fig. 228 Side Gear Thrust Washer Removal:

17. Remove side gear thrust washer (Fig. 228).
18. Inspect all components for excessive wear.