Disassembly

DISASSEMBLY

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

Fig. 166 Differential Cover Bolts:

Fig. 167 Remove Differential Cover:

1) Remove the differential cover and bolts (Fig. 166) (Fig. 167).

Fig. 168 Differential Retainer Bolts:

Fig. 169 Remove Bearing Retainer:

2) Remove the differential bearing retainer and bolts (Fig. 168) (Fig. 169).
3) 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.

4) Use Miller Special Tool 5048, 5048-3 Collets, and L-4539-2 Button to remove the differential bearing cone on the extension housing side.

Fig. 170 Position Button and Collets OntoDifferential and Bearing (Ring Gear Side):

Fig. 171 Position Tool 5048 Over Button and Colletsat Differential Bearing (Ring Gear Side):

Fig. 172 Remove Differential Bearing Cone (RingGear Side):

5) Use Miller Special Tool 5048, 5048-4 Collets, and L-4539-2 Button to remove the differential bearing cone on the bearing retainer side (Fig. 170) (Fig. 171) (Fig. 172).
6) Using Miller Special Tool L-4518, remove the differential bearing race from the extension housing.

Fig. 173 Position Bearing Cup Remover Tool inRetainer:

Fig. 174 Remove Bearing Cup:

7) Using Miller Special Tool 6062A, remove the differential bearing race from the bearing retainer (Fig. 173) (Fig. 174).

Fig. 175 Ring Gear-to-Case Bolts:

8) Remove ring gear-to-differential case bolts and floating pinion shaft retainers (Fig. 175).

Fig. 176 Ring Gear Removal:

9) Separate ring gear from differential case (Fig. 176).

Fig. 177 Separating Differential Support withScrewdrivers:

10) Separate differential cover from case using suitable screwdrivers at position (Fig. 177)

Fig. 178 Differential Support Removal:

11) Lift support from case (Fig. 178).

Fig. 179 Side Gear Thrust Washer Removal:

12) Remove side gear thrust washer (Fig. 179).

Fig. 180 Side Gear Removal:

13) Remove side gear (Fig. 180).

Fig. 181 Pinion Shaft Removal:

14) Remove pinion shaft (Fig. 181).

Fig. 182 Pinion Gear and Washer Removal:

15) Remove pinion gears and tabbed washers (Fig. 182).

Fig. 183 Side Gear Removal:

16) Remove differential side gear (Fig. 183).

Fig. 184 Side Gear Thrust Washer Removal:

17) Remove side gear thrust washer (Fig. 184).
18) Inspect all components for excessive wear.