Carrier Disassembly
Carrier Disassembly
NOTE: Before carrier can be disassembled the center disconnect must be disassembled. See Front Axle Center Disconnect.
1. Remove carrier and the center disconnect as described under Axle, Front Drive removal. Front Drive Axle
2. Disassemble center disconnect as described under Front Axle Center Disconnect Disassembly.
3. NOTE: Place a suitable container beneath the axle to catch any draining lubricant as the Axle Service Plugs T95T-4850-A can no longer be used when the axle shaft seals have been removed.
Using Bench Mounted Holding Fixture T57T-500-B, shift the axle so that the left carrier bore is facing up.
4. Remove Axle Service Plug T95T-4850-A2 from left side carrier opening.
5. Remove the left side oil seal using Connector Seal Remover T94P-77001-BH along with Impact Slide Hammer T50T-100-A.
6. Install Housing Spreader Adapter Set T95T-4000-A and suitable spacers.
7. NOTE: The matched numbers or letters stamped on the cap and carrier must correspond in both position and direction upon assembly.
Remove and clean all gasket surfaces and remove the bearing caps.
8. NOTE: Do not spread the carrier over 0.25mm (0.010 inch).
Mount Differential Housing Spreader TOOL-4000-E or equivalent and Housing Spreader Adapter Set T95T-4000-A on carrier. Place Dial Indicator with Bracketry TOOL-4201-C or equivalent on the carrier and spread the housing.
9. CAUTION: Avoid damaging any machined surfaces.
Remove the differential case from the carrier. It may be necessary to pry the case from the carrier with pry bars.
10. Remove and tag differential bearing cups to indicate from which side of the carrier they were removed.
11. Remove the spreader tool.
12. Turn the nose of the carrier up. Hold the rear axle companion flange with Companion Flange Holding Tool T57T-4851-B and remove the pinion nut and washer from the pinion shaft.
13. Remove the rear axle companion flange with Differential Side Bearing Puller T77F-4220-B1. If the rear axle companion flange shows any signs of wear in the area of seal contact, replace the rear axle companion flange.
14. WARNING: GEAR TEETH MAY HAVE SHARP EDGES. WHEN HANDLING GEAR, USE CARE TO AVOID PERSONAL INJURY.
Remove the drive pinion by tapping on the drive pinion shaft with a rawhide or plastic hammer. Catch the pinion to prevent damage to the pinion teeth.
15. Remove the pinion seal from the carrier bore by using suitable seal puller and Impact Slide Hammer T50T-100-A. Replace the oil seal with a new seal during assembly.
16. Remove the front pinion bearing cone and roller, oil slinger and collapsible spacer from the carrier. Discard the spacer. Replace with a new spacer upon assembly.
17. CAUTION: Use of brass drift may score or gouge the bore. In this event, use a stone to smooth the gouged or scored surface.
To remove the rear drive pinion bearing cup and oil baffle, use a suitable brass drift to drive out the inner cup.
18. NOTE: An oil baffle is located between the rear drive pinion bearing cup and carrier bore. Replace with a baffle of equal thickness. If a baffle of the same thickness cannot be obtained, select adjustment shims, located behind the head of the pinion, to compensate for the difference.
Remove the oil baffle from the inner bearing cup bore.
19. To remove the front drive pinion bearing cup, pass the Outer Pinion Bearing Cup Remover T95T-4628-B and Driver Handle D81L-4000-A or equivalent through the rear bearing cup bore and against the outer bearing cup. Drive the front pinion bearing cup out with a hammer.
20. NOTE: It is recommended that bearings be replaced.
Remove the differential bearings from the case. Place Step Plate D80L-630-4 or equivalent under bearing to protect the bearing. Install Pinion and Carrier Bearing Puller D81L-4220-A or equivalent and remove the bearing. Turn the case over and remove the other bearing.
21. Wire the differential bearing cup, cone and shims together, and identify from which side of the differential case they were removed.
22. NOTE: Place a few shop towels over the vise to prevent the ring gear teeth from being nicked, after it is free from the case.
NOTE: Whenever removing the ring gear bolts, discard the bolts. Replace with new bolts upon assembly.
Place the case in a vise. Remove the ring gear bolts. Tap the ring gear with a plastic hammer to free it from the case.
23. Remove the case and ring gear from the vise.
24. NOTE: For controlling drive pinion depth, an oil slinger with a selected thickness is located between the inner pinion bearing cone and drive pinion head. Be careful not to damage the oil slinger when removing the bearing. If the oil slinger is damaged, measure the thickness and replace with an oil slinger of equal thickness.
Remove the inner differential pinion bearing and oil slinger from the drive pinion with Pinion and Carrier Bearing Puller D81L-4220-A or equivalent.
25. Inspect all parts for damage and replace as required.