Disassembly

DISASSEMBLY
Differential Assembly
1. Remove carrier cover bolts.





2. Separate the carrier cover from the axle housing 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. Remove differential sensor connector bolt and differential lock solenoid connector.





4. 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.

5. Remove adjuster lock plates.





6. Remove side bearing caps.





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





8. Keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusters together with bearing.
9. Remove side bearing adjusters from axle housing.
10. Remove bracket of differential lock position switch connector and bolts.
11. Remove differential lock position switch.





12. Remove side bearing inner race and washer using Tool.
Tool number: ST33081000 ( - )

CAUTION: Do not damage differential case assembly and differential lock solenoid.

13. Remove differential lock solenoid and solenoid washer.





14. Remove side bearing inner race using Tool.
Tool number: ST33081000 ( - )

CAUTION: Do not damage differential case assembly.





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

CAUTION: For matching mark, use paint. Do not damage differential case and drive gear.

16. Remove drive gear bolts.
17. Tap drive gear off differential case assembly using suitable tool.

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

Drive Pinion Assembly
1. Remove differential case assembly.





2. Remove drive pinion nut and washer using Tool.
Tool number: KV40104000 ( - )





3. Put a matching mark on the thread edge of drive pinion. The mark should be in line with the mark on companion flange.

CAUTION: For matching mark, use paint. Do not damage 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 axle housing.

6. Remove front bearing thrust washer.





7. Remove drive pinion assembly and collapsible spacer from axle housing using press.

CAUTION: Do not drop drive pinion assembly.

8. Remove drive pinion front bearing inner race from axle housing.





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

CAUTION: Do not damage axle housing.

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

CAUTION: Do not damage axle housing.





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