Disassembly

DISASSEMBLY

Differential Assembly
1. Drain gear oil, if necessary.
2. Remove carrier cover bolts.





3. 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.





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

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





5. Remove side bearing caps.





6. Remove differential case assembly with using suitable tool.





^ Keep side bearing outer races together with inner race. Do not mix them up.
Also, keep side bearing adjusting washers together with bearings.





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

CAUTION:
^ Engage puller jaws in groove to prevent damage.
^ To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
^ It is not necessary to remove side bearing inner race except if it is replaced.





8. For proper reinstallation, paint matching mark on one differential case assembly.

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

9. Remove drive gear bolts.
10. Tap drive gear off differential case assembly.

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





11. Remove lock pin of pinion mate shaft with punch from drive gear side.





12. Remove pinion mate shaft.





13. 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 differential assembly.





2. Remove drive pinion lock nut using Tool.
Tool number: KV38108300 ( - )





3. 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: For matching mark, use paint. Do not damage companion flange and 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.





4. Remove companion flange using suitable Tool.





5. Remove drive pinion assembly from axle housing using suitable tool.

CAUTION: Do not drop drive pinion assembly.

6. Remove front oil seal.
7. Remove drive pinion front bearing inner race.
8. Remove collapsible spacer.





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





10. Tap drive pinion front/rear bearing outer races uniformly a brass rod or equivalent.

CAUTION: Do not damage axle housing.