Differential Housing Assembly - Disassemble

DIFFERENTIAL HOUSING ASSEMBLY - DISASSEMBLE

^ TOOLS REQUIRED
- J22912-A Bearing Puller
- J3289-20 Base
- J3940 Race Installer
- J44854 Side gearing Remover
- J44855 Side Bearing Installer
- J44858 Pinion Bearing Remover
- J44864 Pinion Nut Wrench
- J44865 Spline Socket
- J44869 Assembly Holding Fixture





1. Remove drain plug and drain the fluid.





2. Remove the fill plug.





3. Remove rear mounting bracket (2) and bolts (3).





4. Remove nut (1) and flange (2). Discard used nut.





5. Remove dust deflector (2) from flange (1), if required.





6. Remove input flange oil seal (1) from clutch cover.





7. Remove bolts (1) and clutch cover (2) from differential housing.





8. Remove filter assembly.
9. Remove dowel pins.

NOTICE: Inspect press bar surface. Do not press housing against a rough surface. Sealing surface could be damaged.





10. Position clutch cover (1) into a press in order to remove clutch drum.

NOTICE: Do not submerge clutch drum in solvent. This will damage friction material and geroter pump.

IMPORTANT: The clutch drum is not serviceable. If inoperative conditions are found replace unit.





11. Remove clutch drum (2) from clutch cover (1).





12. Remove snap ring (1) from clutch cover.





13. Remove bearing (1), and clutch drum front oil seal (2) from clutch cover.
14. Remove clutch drum rear oil seal (1) from housing.





15. Attach Assembly Holding Fixture J44869 to the housing, using 4 clutch cover bolts.
16. Install housing and fixture into Base J3289-20 (2) base.





17. Remove rear cover bolts, 4 (M8) and 4 (M10).

NOTICE: Use pry point only. Do not pry on the sealing surface.

IMPORTANT: The rear differential carrier may come out with the cover.





18. Remove rear cover by prying it off at the pry point locations.





19. Remove right and left axle shaft oil seals.





20. Remove differential carrier, place a screwdriver in axle differential bore and pry up.

IMPORTANT: Mark or tag bearing races and shims for assembly.





21. Remove carrier assembly (1), bearing races (2), and shims (3).

IMPORTANT: The ring gear bolts are not to be reused. Use new bolts during assembly.





22. Remove bolts (3) and ring gear (1) from carrier (2).





23. Identify lock pin location (1) within the differential case.





24. Remove pinion shaft roll pin (3) and the 1-pin (2) from the differential case (1).





25. Remove washers (1), pinion gears (2) and side gears (3) from differential case.





26. Using Sidle Bearing Remover J44854 (3), Bearing Puller J22912-A.(2), and Side Bearing Installer J44855(1), place carrier into a press and press off bearing.
27. Turn carrier over, using same, remove right side differential bearing.





28. Using a punch, bend out flat on both sides of the pinion nut.





29. Place Pinion Nut Wrench J44864 (1) over pinion shaft. Turn shaft to align hex nut with the flat on Assembly Holding Fixture J44869 (2).





30. Place Spline Socket J44865 (1) and breaker bar over pinion splines. Remove nut.

IMPORTANT: Pinion nut is not reusable.





31. Remove Pinion Nut Wrench J44864 (1) and nut.
32. Remove the 4 bolts from Assembly Holding Fixture J44869 (2), and remove Assembly Holding Fixture J44879 from housing.

NOTICE: Inspect press bar surface. Do not press housing against a rough surface. Sealing surface could be damaged.





33. Position differential housing into a press in order to remove pinion shaft.

IMPORTANT: The collapsible spacer is not reusable.





34. Remove front bearing (1), the collapsible spacer (2), and the pinion shaft (3).

NOTICE: Inspect press bar surface. Do not press housing against a rough surface. Sealing surface could be damaged.

IMPORTANT: The bolt is left-hand threaded.





35. Place Race Installer J3940 behind rear pinion bearing race in the grooves. Spread the arms and tighten lock bolt.
36. Place housing in a Dress and remove race.

NOTICE: If dowel pins are still in housing remove them before pressing. Pressing on dowels will damage housing.





37. Place J3940 behind front bearing race in the grooves. Spread the arms and tighten lock bolt.
38. Place housing in a press and remove the race.





39. Using Pinion Bearing Remover J44858 (2), and Bearing Puller J22912-A (1), place the V of the split plate in the groove of Pinion Bearing Remover J44858 (2). Tighten nuts.

IMPORTANT: The pinion shaft is located under the bearing. Measure and mark or tag when removed.

40. Place pinion shaft and tools in a press, remove bearing and shim.