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 bolts (1).




Figure 2 Remove Differential Cover






2. Remove the differential cover (2).




Figure 3 Differential Retainer Bolts


1 - DIFFERENTIAL RETAINER BOLTS

3. Remove the differential bearing retainer bolts (1).




Figure 4 Remove Bearing Retainer






4. Remove the differential bearing retainer (1).




Figure 5 Position Button and Collets Onto Differential and Bearing (Ring Gear Side)






5. 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.

6. Use Puller Set 5048 (2), 5048-3 Collets (3), and L-4539-2 Button (1) to remove the differential bearing cone on the extension housing side.




Figure 6 Position Puller Set 5048 Over Button and Collets at Differential Bearing (Ring Gear Side)






7. Install Puller Set 5048 (1), 5048-4 Collets (3), and L-4539-2 Button (1) to the differential bearing cone on the bearing retainer side.




Figure 7 Remove Differential Bearing Cone (Ring Gear Side)






8. Remove the differential bearing cone on the bearing retainer side.




Figure 8 Position Bearing Cup Remover Tool in Retainer






9. Install Special Jaw Set L-4518 and Remover 6062A (1), onto the differential bearing race from the extension housing.




Figure 9 Remove Bearing Cup






10. Remove the differential bearing race from the bearing retainer (2).




Figure 10 Ring Gear-to-Case Bolts






11. Remove ring gear-to-differential case bolts (4) and floating pinion shaft retainers (2).




Figure 11 Ring Gear Removal






12. Separate ring gear (2) from differential case (1).




Figure 12 Separating Differential Support with Screwdrivers






13. Separate differential cover (1) from case (2) using suitable screwdrivers at position.




Figure 13 Differential Support Removal






14. Lift support (1) from case (2) (Figure 13).




Figure 14 Side Gear Thrust Washer Removal


1 - SIDE GEAR THRUST WASHER

15. Remove side gear thrust washer (1) (Figure 14).




Figure 15 Side Gear Removal


1 - DIFFERENTIAL SIDE GEAR

16. Remove side gear (1) (Figure 15).




Figure 16 Pinion Shaft Removal


1 - PINION SHAFT

17. Remove pinion shaft (1) (Figure 16).




Figure 17 Pinion Gear and Washer Removal






18. Remove pinion gears (1) and tabbed washers (2) (Figure 17).




Figure 18 Side Gear Removal


1 - DIFFERENTIAL SIDE GEAR

19. Remove differential side gear (1) (Figure 18).




Figure 19 Side Gear Thrust Washer Removal


1 - THRUST WASHER

20. Remove side gear thrust washer (1) (Figure 19).
21. Inspect all components for excessive wear.