Disassembly

DISASSEMBLY

EXCEPT STI MODEL





To detect the real cause of trouble, inspect the following items before disassembling.
^ Tooth contact of hypoid driven gear and pinion, and backlash
^ Runout of hypoid driven gear at its back surface
^ Total preload of drive pinion
1) Set the ST on vise and install the differential assembly to ST.
ST 398217700 ATTACHMENT





2) Drain the gear oil by removing the plug.
3) Remove the air breather cap.

NOTE:
^ Do not attempt to remove the air breather cap if unnecessary.
^ When removing the air breather cap, replace the air breather cap with a new one.





4) Remove the bolts, and then remove the rear cover.

NOTE:
Remove it by tapping with plastic hammer.





5) Make right and left side bearing retainers in order to identify them at reassembly. Remove the side bearing retainer attaching bolts, set the ST to differential case, and extract right and left side bearing retainers with a puller.

NOTE:
Each shim, which is installed to adjust the side bearing preload, should be kept together with its mating retainer.

ST 398457700 ATTACHMENT





6) Pull out the differential case assembly from differential carrier.

NOTE:
Be careful not to hit the teeth against the case.

7) When replacing the side bearing, pull the bearing cup from side bearing retainer using ST.
ST 398527700 PULLER ASSY





8) Extract the bearing cone with ST.

NOTE:
^ Do not attempt to disassemble the parts unless necessary.
^ Set the puller so that its claws catch the edge of bearing cone.
^ Never mix up the right and left hand bearing races and cones.
ST 18759AA000 PULLER ASSY





9) Remove the hypoid driven gear by loosening the hypoid driven gear bolts.





10) Drive out the pinion shaft lock pin from hypoid driven gear side. (Model without LSD)

NOTE:
The lock pin is staked at the pin hole end on the differential carrier; do not drive it out forcibly before unstaking it.

ST 899904100 STRAIGHT PIN REMOVER





11) Draw out the pinion mate shaft and remove the pinion mate gears, side gears and thrust washers. (Model without LSD)

NOTE:
The gears as well as thrust washers should be marked or kept separated right and left, front and rear.





12) Hold the companion flange with ST and remove self-locking nut.
ST 498427200 FLANGE WRENCH





13) Extract the companion flange with a puller.





14) Press the end of drive pinion shaft and extract it together with the rear bearing cone, preload adjusting spacer and washer.

NOTE:
Hold the drive pinion so as not to drop it.
ST 398467700 DRIFT





15) Remove the rear bearing cone from drive pinion by supporting the cone with ST.

NOTE:
Place the replacer so that its center-recessed side faces the pinion gear.
ST 398517700 REPLACER





16) Remove the front oil seal from differential carrier using ST.
ST 398527700 PULLER ASSY





17) Remove the pilot bearing together with front bearing cone and spacer using ST.
ST 398467700 DRIFT





18) When replacing the bearings, hit out the front bearing cup and rear bearing cup in this order out of case by using a brass bar.