Disassembly

DISASSEMBLY




Figure 1 Differential Cover Bolts







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

1. Remove the differential cover and bolts (1) (Figure 1).




Figure 2 Differential Retainer Bolts


1 - DIFFERENTIAL RETAINER BOLTS

2. Remove the differential bearing retainer bolts (1) (Figure 2).




Figure 3 Remove Bearing Retainer






3. Remove the differential bearing retainer (1) (Figure 3) using Bearing Puller L-4435 (2).




Figure 4 Checking Side Gear End Play (Extension Housing Side)






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.
6. Set up Dial Indicator Set C-3339 (2) and Adapter C-4996 (1) (Figure 4) to measure side gear end play (Extension Housing Side). Side gear end play must be within 0.001-0.013 in.




Figure 5 Checking Side Gear End Play (Ring Gear Side)






7. Set up Dial Indicator Set C-3339 (2) and Adaptor C-4996 (1) (Figure 5) to measure side gear end play (Ring Gear Side). Side gear end play must be within 0.001-0.013 in.




Figure 6 Button L-4539-2 and Collets 5048-4






8. Remove differential side bearing cone (3) (Figure 6) from ring gear side of differential. Install Thrust Button L-4539-2 (2), and Collets 5048-4 (1).




Figure 7 Side Bearing Removal Using Tool 5048 (Ring Gear Side)






9. Install Puller Set 5048 (1) (Figure 7), Collets 5048-4 (2) and sleeve. Remove and discard bearing cone.




Figure 8 Install Button L-4539-2


1 - BUTTON L-4539-2

10. Remove differential side bearing cone from outboard end (opposite ring gear) of differential. Install Thrust Button L-4539-2 (1) (Figure 8).




Figure 9 Side Bearing Removal Using Tool 5048






11. Install Puller Set 5048 (1) (Figure 9), (2) Collets 5048-3 and sleeve. Remove and discard bearing cone.




Figure 10 Remove/Install Retainer/Ring Gear Bolt


1 - PINION SHAFT RETAINER

12. Remove pinion shaft retainer plate bolts (1) (Figure 10).




Figure 11 Pinion Shaft Retainer


1 - PINION SHAFT RETAINER

13. Remove pinion shaft retainer (1) (Figure 11).




Figure 12 Pinion Shaft Removal/Installation


1 - PINION SHAFT

14. Remove pinion shaft (1) (Figure 12) from differential case.




Figure 13 Pinion Gear and Washer






15. Rotate pinion gears (2) (Figure 13) about case and remove (w/washer) (1).




Figure 14 Side Gear Removal/Installation


1 - SIDE GEAR

16. Remove differential side gears (1) (Figure 14).




Figure 15 Side Gear Washer


1 - SIDE GEAR THRUST WASHER

17. Remove side gear thrust washers (1) (Figure 15).




Figure 16 Ring Gear Bolt Removal/Installation


1 - RING GEAR BOLTS

18. Remove remaining differential ring gear-to-case bolts (1) (Figure 16).




Figure 17 Ring Gear Removal






19. Using a soft-faced hammer (1) (Figure 17), remove ring gear (2) from case.




Figure 18 Position Bearing Cup Remover Tool in Retainer






20. Using Remover 6062A(Figure 18), remove the differential bearing race from the extension housing/adapter plate.




Figure 19 Remove Bearing Cup






21. Using Remover 6062A (Figure 19), remove the differential bearing race from the bearing retainer.

Differential Service Tools: