Disassembly

DISASSEMBLY
Side Shaft
1. Drain gear oil, if necessary.





2. Remove side oil seal using suitable tool.

CAUTION: Do not damage gear carrier.





3. Remove snap ring (hole side) using suitable tool.





4. Remove side shaft assembly out of gear carrier using suitable tool.

NOTE: Tap on side shaft assembly from side gear side.

5. Remove snap ring (shaft side).





6. Press side shaft out of side shaft bearing.

CAUTION: Do not drop side shaft.

Differential Assembly
1. Remove side shaft assembly.
2. Remove rear cover bolts.





3. Separate the rear cover from the gear carrier 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.





4. For proper reinstallation, paint matching marks on one side of the bearing cap.

CAUTION:
^ For matching mark, use paint. Do not damage bearing caps and gear carrier.
^ Bearing caps are line-board during manufacture. The matching marks are used to reinstall them in their original positions.





5. Remove bearing caps using suitable tool.





6. Lift differential case assembly out using suitable tool.





CAUTION:
^ Keep side bearing outer races together with inner race. Do not mix them up.
^ Keep side bearing adjusting washers together with bearings.

7. Remove housing spacer.





8. Remove side bearing inner races, using Tools.
Tool number
A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)

CAUTION:
^ Place copper plates between the side bearing and drive gear and the vise to prevent damage.
^ Do not remove side bearing inner race unless it is being replaced.





9. For proper reinstallation, paint matching mark on one side of differential case assembly.

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

10. Remove drive gear bolts.
11. Tap drive gear off differential case assembly using suitable tool.

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





12. Remove lock pin of pinion mate shaft from drive gear side using suitable tool.





13. Remove pinion mate shaft.





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

Drive Pinion Assembly
1. Remove side shaft assembly.
2. Remove differential assembly.





3. Remove drive pinion lock nut using Tool.
Tool number: KV38108300 (J-44195)





4. Put matching mark on the end of drive pinion. The matching mark should be in line with the matching mark A on companion flange.

CAUTION: Use paint for matching mark. Do not damage companion flange or drive pinion.

NOTE: The matching mark A on the final drive companion flange indicates the maximum vertical runout position.
When replacing companion flange, matching mark is not necessary.





5. Remove companion flange using suitable tool.





6. Press drive pinion assembly out of gear carrier. (Together with collapsible spacer.)

CAUTION: Do not drop drive pinion assembly.





7. Remove pinion rear bearing inner race and drive pinion height adjusting washer using Tool.
Tool number: ST30031000 (J-22912-01)





8. Remove front oil seal using suitable tool.

CAUTION: Do not damage gear carrier.

9. Remove pinion front bearing inner race.
10. Remove collapsible spacer.





11. Tap pinion front/rear bearing outer races uniformly to remove them, using suitable tool.

CAUTION: Do not damage gear carrier.