Disassemble

NOTE: Refer to inspection procedures before disassembling the differential.
Component Inspection





1. Remove the bolts in a crisscross pattern, in several steps, then remove the differential case cover.





2. Remove the oil seal from the differential case cover.





3. Remove the bearing outer race and the 75 mm thrust shim from the differential case cover by driving them out or by heating the differential case cover to about 212°F (100°C).

CAUTION: Do not reuse the 75 mm thrust shim if the bearing outer race was driven out.

NOTE:
* Do not heat the differential case cover in excess of 212°F (100°C).
* If the bearing outer race was removed by heating, allow the differential cover to cool to room temperature.
* Replace the tapered roller bearing with a new one whenever the bearing outer race is replaced.





4. Remove the breather chamber plate and the oil collect plate.





5. Remove the differential carrier from the differential case.





6. Remove the oil cooler.





7. Raise the locknut tab from the groove of the drive pinion.

CAUTION: Make sure that the tab completely clears the groove to prevent damaging the drive pinion threads.





8. Hold the drive pinion using a 1 1/4" (32 mm) hex bit and socket as shown.





9. Remove the locknut and the spring washer from the drive pinion.

NOTE: The locknut has left-hand threads.





10. Remove the pinion collar and the oil seal, then tap the drive pinion through the tapered roller bearing.





11. Remove the drive pinion, the pinion spacer, and the thrust washers.





12. Remove the tapered roller bearing and 40 mm thrust shim using a press as shown.





13. Remove the bearing outer races, 75 mm thrust shim, and thrust washers by driving them out from behind using the grooves provided or by heating the differential case to about 212°F (100°C).

NOTE: Use care when driving out the bearing outer races to prevent damage to the differential case.

CAUTION: Do not reuse the 75 mm thrust shim and thrust washer if the bearing outer race was driven out.

NOTE:
* Do not heat the differential case in excess of 212°F (100°C).
* If the bearing outer race was removed by heating, allow the differential case to cool to room temperature.
* Replace the tapered roller bearing with a new one whenever the bearing outer race is replaced.

14. Proceed to Differential Carrier service procedures.
Differential Carrier Assembly