Differential Carrier Overhaul

DISASSEMBLY PROCEDURE

^ Tools Required
- J 8107-2 Differential Side Bearing Remover
- J 8614-01 Pinion Yoke Holder
- J 21551 Output Shaft Bearing Remover
- J 22888-20 Differential Side Bearing Puller
- J 22912-01 Pinion Bearing Remover
- J 23907 Slide Hammer
- J 29369-1 Universal Bearing Remover
- J 33791 Bushing Remover and Installer Set
- J 33792 Side Bearing Adjuster Socket
- J 33837 Pinion Bearing Cup Remover and Installer
- J34011 Pilot Bearing Remover
- J 36611 Output Shaft Bearing Remover
- J 42213 Side Bearing Adjuster Socket





1. Remove the bolts, the shift cable housing, and the spring.
2. Remove the tube and the thrust washer.
3. Remove the spring and shift shaft with fork.
4. Remove the axle shaft.
5. Remove the clutch gear with the retaining ring.
6. Remove the right inner axle shaft to housing seal using a suitable seal remover.
7. Remove the right inner axle shaft bearing using the J 29369-1 and the J 23907.
8. Remove the thrust washer.
9. Remove the clutch sleeve and shaft.





10. Remove the pilot bearing from the clutch shaft using the J34011.
11. Remove the washer.
12. Remove the left side carrier cover bolts.
13. Remove the left side cover and seal assembly.
14. Remove the carrier halves assembly bolts.





15. Separate the carrier. Insert a screwdriver into the slots provided and pry in order to separate the carrier.
16. Remove the differential case assembly.





17. Remove the bolts and lock tabs from the side bearing adjuster sleeves.
18. Remove the bearing cups and sleeves from the carrier.





19. Turn the left sleeve until the cup is pushed out of the carrier using the J 42213.





20. Turn the right sleeve until the cup is pushed out of the carrier using the J 33792.





21. Remove the bearing from the right adjuster sleeve using the J21551.





22. Remove the bearing from the left adjuster sleeve using the J 36611.





23. Remove the pinion yoke nut and washer using the J 8614-01.





24. Mount the left carrier case half and drive the pinion out of the carrier using the J 33837 -1 and the J 33837-3
25. Remove the pinion yoke and the deflector.
26. Remove the pinion with the spacer and the pinion bearing and shim.
27. Remove the spacer from the pinion.





28. Remove the bearing from the pinion with a press and the J 22912-01.
29. Remove the shim.
30. Remove the outer pinion bearing, the seal and the cup using the J 33837-1, the J 33837-3 and the J 33837-6.
30.1. Insert the J 33837-6 into the pinion bore.
30.2. Thread the forcing screw (J 33837-3) into the J 33837-6.
30.3. In order to pull the parts from the case, turn the forcing screw.





31. Remove the inner bearing cup by pushing out using the J 33837-1, the J 33837-3 and the J 33837-6.
32. Remove the differential pinion bolt and shaft from the differential case.
33. Remove the differential pinion gears and the thrust washers.
34. Remove the side gears and the thrust washers. Mark the side gears and case for reinstallation in the original location.
35. Remove the ring gear mounting bolts.
36. Remove the ring gear. Drive the gear off using a brass drift and hammer. Do not pry between the ring gear and the case.





37. Remove the side bearings using the J 22888-20 and the J 8107-2.





38. Remove the case bushing using the J 33791-1 and the J 33791-2.