Disassembly

DISASSEMBLY

Differential Assembly
1. Remove carrier cover bolts.





2. Remove carrier cover using Tool.
Tool number: KV10111100 (J-37228)

CAUTION:
^ Do not damage the mating surface.
^ Do not insert flat-bladed screwdriver, this will damage the mating surface.





3. For proper reinstallation, paint matching mark on one side of side bearing cap.

CAUTION:
^ Side bearing caps are line-board for initial assembly. The matching marks are used to reinstall them in their original positions.
^ For matching mark, use paint. Do not damage side bearing cap.

4. Remove adjuster lock plates.





5. Remove side bearing caps.





6. Remove side bearing adjusters using Tool.
Tool number: - (C - 4164)





7. Keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusters together with bearing.
8. Remove side bearing adjusters from gear carrier.





9. Remove side bearing inner races using suitable puller.

CAUTION: Do not damage differential case.





10. For proper reinstallation, paint matching mark on differential case and drive gear.

CAUTION: Use paint for matching marks. Do not damage differential case or drive gear.

11. Remove drive gear bolts.
12. Tap the drive gear off the differential case using suitable tool.

CAUTION: Tap evenly all around to keep drive gear from binding.





13. Remove the lock pin of the pinion mate shaft from the drive gear side using Tool.
Tool number: ST23550000 ( - )





14. Remove the pinion mate shaft.





15. Turn the pinion mate gear, then remove the pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from differential case.

Drive Pinion Assembly
1. Remove differential case assembly.





2. Remove drive pinion lock nut and washer using Tool.
Tool number: KV40104000 ( - )
3. Put matching marks on the companion flange and drive pinion using paint.

CAUTION: Use paint to make the matching marks. Do not damage the companion flange or drive pinion.





4. Remove companion flange using suitable Tool.





5. Remove front oil seal using Tool.
Tool number: ST33290001 (J-34286)

CAUTION: Do not damage gear carrier.

6. Remove drive pinion front bearing thrust washer.





7. Remove drive pinion assembly (with rear inner bearing race and collapsible spacer) out of gear carrier.

CAUTION: Do not drop drive pinion assembly.

8. Remove drive pinion front bearing inner race from gear carrier.





9. Tap drive pinion front bearing outer race uniformly with a brass bar or equivalent to remove.

CAUTION: Do not damage gear carrier.

10. Tap drive pinion rear bearing outer race uniformly with a brass bar or equivalent for removal.

CAUTION: Do not damage gear carrier.





11. Remove drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool.
Tool number: ST30021000 (J-22912-01)