Disassembly

FINAL DRIVE

DISASSEMBLY

NOTE: The transfer shaft should be removed for differential repair and bearing turning torque checking.

Fig. 168 Differential Cover Bolts:

1) Remove the differential cover and bolts (1) (Fig. 168).

Fig. 169 Differential Retainer Bolts:

2) Remove the differential bearing retainer bolts (1) (Fig. 169).

Fig. 170 Remove Bearing Retainer:

3) Remove the differential bearing retainer (1) (Fig. 170) using Holder L-4435 (2).
4) Using a plastic hammer, remove extension housing/adapter plate on the right side of the transaxle.

WARNING: Hold onto differential assembly to prevent it from rolling out of housing.

5) Remove differential assembly.

Fig. 171 Checking Side Gear End Play (ExtensionHousing Side):

6) Set up Dial Indicator Set C-3339 (2) and Adapter C-4996 (1) (Fig. 171) to measure side gear end play (Extension Housing Side). Side gear end play must be within 0.001 - 0.013 inch.

Fig. 172 Checking Side Gear End Play (Ring GearSide):

7) Set up Dial Indicator Set C-3339 (2) and Adapter C-4996 (1) (Fig. 172) to measure side gear end play (Ring Gear Side). Side gear end play must be within 0.001-0.013 in.

Fig. 173 Button L-4539-2 and Collets 5048-4:

8) Remove differential side bearing cone (3) (Fig. 173) from ring gear side of differential. Install button L-4539-2 (2), and Collets 5048-4 (1).

Fig. 174 Side Bearing Removal Using Tool 5048(Ring Gear Side):

9) Install Puller Set 5048 (1) (Fig. 174), collets 5048-4 (2) and sleeve. Remove and discard bearing cone.

Fig. 175 Install Button L-4539-2:

10) Remove differential side bearing cone from outboard end (opposite ring gear) of differential. Install Button L-4539-2 (1) (Fig. 175).

Fig. 176 Side Bearing Removal Using Tool 5048:

11) Install Puller Set 5048 (1) (Fig. 176), (2) collets 5048-3 and sleeve. Remove and discard bearing cone.

Fig. 177 Remove/Install Retainer/Ring Gear Bolt:

12) Remove pinion shaft retainer plate bolts (1) (Fig. 177).

Fig. 178 Pinion Shaft Retainer:

13) Remove pinion shaft retainer (1) (Fig. 178).

Fig. 179 Pinion Shaft Removal/Installation:

14) Remove pinion shaft (1) (Fig. 179) from differential case.

Fig. 180 Pinion Gear and Washer:

15) Rotate pinion gears (2) (Fig. 180) about case and remove (w/washer) (1).

Fig. 181 Side Gear Removal/Installation:

16) Remove differential side gears (1) (Fig. 181).

Fig. 182 Side Gear Washer:

17) Remove side gear thrust washers (1) (Fig. 182).

Fig. 183 Ring Gear Bolt Removal/Installation:

18) Remove remaining differential ring gear-to-case bolts (1) (Fig. 183).

Fig. 184 Ring Gear Removal:

19) Using a soft-faced hammer (1) (Fig. 184), remove ring gear (2) from case.

Fig. 185 Position Bearing Cup Remover Tool inRetainer:

20) Using Jaw Set 6062A (Fig. 185), remove the differential bearing race from the extension housing/ adapter plate.

Fig. 186 Remove Bearing Cup:

21) Using Jaw Set 6062A (Fig. 186), remove the differential bearing race from the bearing retainer.

DIFFERENTIAL SERVICE TOOLS: