REAR DIFFERENTIAL DISASSEMBLY

id031400146500

Special Service Tool (SST)

49 0107 680A   Engine stand		49 L027 0A2   Diff hanger set		49 T032 317   Weight
49 T032 316   Shaft		49 L027 004   Gear case remover		49 L027 006   Serrate socket
49 L027 007   Hex socket		49 H027 002   Bearing remover		49 0839 425C   Bearing puller set

Warning

•  The engine stand is equipped with a self-lock mechanism, however, if the rear differential is in a tilted condition, the self-lock mechanism could become inoperative. If the rear differential unexpectedly rotates it could cause injury, therefore do not maintain the rear differential in a tilted condition. When turning the rear differential, grasp the rotation handle firmly.

1.  Disassemble in the order indicated in the table.

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1	Differential oil temperature sensor
2	Rear cover (See Rear Cover Disassembly Note.)
3	Rear differential component (See Rear Differential Component Disassembly Note.)
4	Adjusting shim
5	Spacer
6	Oil seal (Coupling component)
7	Locknut (See Locknut Disassembly Note.)
8	Drive pinion (See Drive Pinion Disassembly Note.)
9	Collapsible spacer
10	Bearing inner race (front)
11	Bearing inner race (rear) (See Bearing Inner Race (Rear) Disassembly Note.)
12	Spacer
13	Bearing outer race (See Bearing Outer Race Disassembly Note.)
14	Differential carrier
15	Ring gear (See Ring Gear Disassembly Note.)
16	Pin
17	Pinion shaft
18	Pinion gear
19	Thrust washer
20	Side gear
21	Thrust washer
22	Side bearing (See Side Bearing Disassembly Note.)
23	Gear case
24	Oil seal (side gear)

Rear Cover Disassembly Note

1.  Install the SSTs to the engine stand.

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2.  Install the rear differential to the SSTs.

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3.  Remove the rear cover.

Rear Differential Component Disassembly Note

1.  If the rear differential component cannot be removed by hand, remove the rear differential component using the SSTs.

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2.  Mark or otherwise distinguish between the removed left and right adjusting shims, spacers and side bearing outer races so that they are not mixed up at the time of reassembly.

Locknut Disassembly Note

1.  Remove the locknut using the SSTs.

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Drive Pinion Disassembly Note

1.  Remove the drive pinion by lightly tapping with a copper hammer.

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Bearing Inner Race (Rear) Disassembly Note

1.  Remove the bearing inner races (rear) using the SST and a press.

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Bearing Outer Race Disassembly Note

1.  Remove the bearing outer races using the 2 grooves in the carrier and alternately tapping the sides of the races with a brass bar.

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Ring Gear Disassembly Note

1.  Secure the gear case in a vise and remove the bolts.

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2.  Lightly tap around the ring gear using a plastic hammer to remove the ring gear from the gear case.

Side Bearing Disassembly Note

Caution

•  Mark or otherwise distinguish between the left and right side bearings so that they are not mixed up at the time of reassembly.

1.  Remove the side bearing inner races from the gear case using the SST.

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