Inspection

Inspection Procedure
Perform the following checks before disassembling the axle:





1. Remove the drain plug from the axle. Drain the axle lubricant.
2. Check the ring gear backlash. Refer to Backlash Inspection and Adjustment.
This information can be used to determine the cause of the axle problem. The information will also help when setting up the shim packs for locating and preloading the differential case.
3. Inspect the case for metal chips.
Determine the source of the metal chips, such as a broken gear or bearing cage.
4. Determine the cause of the axle problem before disassembly, if possible.

Disassembly Procedure

^ Tools Required
- J29369-1 Bearing Remover (K1 and K2 Models)
- J29369-2 Bearing Remover (K3 Models)
- J23907 Slide Hammer
- J34011 Pilot Bearing Remover
- J36599 Adjusting Sleeve Wrench
- J36615 Adjuster Plug Wrench (K3 Models)
- J8614-01 Pinion Remover
- J36598 Holding Fixture and Pinion Service Tool
- J8612-B Pinion Bearing Remover (K1 and K2 Models)
- J36606 Inner Pinion Bearing Remover Pinion Bearing Remover (K3 Models)
- J22888 Side Bearing Puller
- J8107-2 Side Bearing Puller Pilot (K1 and K2 Models)
- J36597 Side Bearing Puller Pilot K3 Side Bearing Puller Pilot (K3 Models)
- J36616 Bushing Replacer
- J2619-01 Slide Hammer
- J36598 Holding Fixture

1. Remove the differential actuator.
2. Remove the engagement switch.
3. Remove the bolts.
4. Remove the axle tube with the right output shaft.
5. Remove the differential sleeve.
6. Remove the following parts:
^ The shift shaft
^ The damper spring
^ The shift fork
^ The shifter shaft ring

7. Remove the spring.
8. Remove the shim.
9. For the K1, and K2 models, remove the carrier connector with the retainer ring.
9.1. Clamp the axle tube in a vise. Clamp only on the mounting flange.
9.2. Strike the inside of the shaft flange with a brass hammer in order to dislodge the carrier connector.





10. For the K3 models, remove the following parts:
^ The snap ring
^ The washer
^ The thrust washer





11. Remove the right output shaft.





12. Remove the seal and the output shaft bearing.
^ For the K1, and K2 models, use the J29369- 1.
^ For the K3 model, use the J29369-2 or the J23907

13. Remove the output shaft.





14. Use the J34011 in order to remove the differential pilot bearing.





15. Use the J2619-01 in order to remove the left output shaft.
16. Remove the seal.
Pry the seal out with a removal tool.





17. Remove the bearings.
^ For the K1, and K2 models, use the J29369- 1.
^ For the K3 model, use the J29369-2 or the J23907.

18. Remove the bolts.





19. Remove the right side carrier half.
Tap on the cast lugs provided.





20. Remove the differential assembly.
Pry up on the locks.
Pry the right side only on the K3 model.
21. For the K3 model, remove the bolt and the lock.





22. Remove the sleeve(s) and the side bearing cups.
^ Turn the sleeve(s) in order to push the bearing cup(s) out of the bore(s).
^ Use the J36599.
^ For the K3 model, remove the sleeve(s) and side bearing cups only from the right side.





23. For the K3 model, use the J36615 in order to remove the adjuster plug with the side bearing cup and the O-ring seal.





24. Remove the nut.
Use the J8614-01 in order to hold the pinion flange.
25. Remove the washer.
26. Use the J8614-01 in order to remove the pinion flange with the deflector.





27. Mount the left carrier case in the J36598.
For the K1, and K2 models, use the adapter plate J36598.
28. Use the J36598 in order to remove the ring and pinion with the following parts:
^ The shim
^ The bearing cone
^ The spacer

29. Remove the spacer from the pinion.





30. Remove the pinion bearing.
^ For the K1, and K2 models, use the J8612-B.
^ For the K3 model, use the J36598 and a press.

31. Remove the shim.





32. Use the J36598 in order to remove the following parts:
^ The seal
^ The bearing cup
^ The cone





33. Use the J36615 in order to remove the bearing cup.





34. Remove the side bearings.
^ For the K1, and K2 models, use the J22888 and the J8107-2.
^ For the K3 model, use the J36597 Side Bearing Puller Pilot (K3) and a press.

Notice: Do not pry the ring gear from the case. This will damage the ring gear and the differential case.

35. Remove the ring gear bolts. The ring gear bolts have left-handed threads.





36. Remove the ring gear from the differential case. Drive the ring gear off with a brass drift.





37. For the K1, and the K2 models, remove the pin. Use a drift and a hammer in order to drive out the pin.





38. For the K3 model, remove the bolt.
39. Remove the shaft.
40. Remove the differential pinion gears and the side gears.
40.1. Roll the pinion gears out of the case with the pinion thrust washers.
40.2. Remove the side gears and the side gear thrust washers. Mark the gears and the differential case as left and right.
40.3. For the K3 model, remove the spacer.
41. Remove the vent plug. Use a 6-point deep socket.





42. Use the J36616 in order to remove the bushings.

Inspection Procedure
Thoroughly and carefully inspect all of the drive units before assembly. Thorough inspection of the parts for wear or stress and replacement of worn parts will help prevent costly drive component repair after the reassembly.

Axle Housing Inspection
1. Inspect the axle housing bore for nicks or burrs that would prevent the outer diameter of the pinion seal from sealing. Remove any burrs.
2. Inspect the bearing cup surfaces for nicks or burrs. Remove any burrs.
3. Replace the housing if any cracks are found.
4. Inspect the housing for the following materials:
^ Metal chips
^ Dirt
^ Rust

5. If the above materials are found. Refer to Cleaning Carrier Components.

Differential Inspection
1. Inspect the pinion gear shaft for unusual wear.
2. Inspect the pinion gear and the side gear teeth for the following conditions:
^ Wear
^ Cracks
^ Scoring
^ Spalling

3. Inspect the thrust washers for wear.
4. Inspect the fit of the differential side gears in the differential case.
5. Inspect the fit of the side gears on the axle shafts.
6. Inspect the differential case for cracks and scoring.
7. Inspect all the parts for wear. Replace as necessary.