Differential Carrier Overhaul

^ Tools Required
- J8107-2 Differential Side Bearing Remover
- J8614-01 Pinion Flange Holder
- J21551 Output Shaft Bearing Remover
- J22888-20 Differential Side Bearing Puller
- J22912-01 Pinion Bearing Remover
- J23907 Slide Hammer
- J29369-1 Universal Bearing Remover
- J33791 Bushing Remover and Installer Set
- J33792 Side Bearing Adjuster Wrench
- J33837 Pinion Bearing Cup Remover and Installer
- J36611 Output Shaft Bearing Remover
- J42213 Side Bearing Adjuster Socket

1. Remove the right inner axle shaft and the retaining ring.
2. Remove the axle tube to carrier mounting bolts.
3. Remove the axle tube.
4. Remove the right inner axle shaft to housing seal using a suitable seal remover.





5. Remove the right inner axle shaft bearing using the J29369-1 and the J23907
6. Pull the output shaft from the carrier.
7. Remove the left side carrier bolts.
8. Remove the left side cover and seal assembly.
9. Remove the carrier halves assembly bolts.





10. Separate the carrier case. Insert a screwdriver into the slots provided and pry the carrier case apart.
11. Remove the differential case assembly.





12. Remove the bolts and the lock tabs from the side bearing adjuster sleeves.
13. Remove the bearing cups and sleeves from the carrier.





14. Turn the left sleeve using the J42213 until the cups are pushed out of the carrier.





15. Turn the right sleeve using the J33792 until the cup is pushed out of the carrier.





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





17. Remove the bearing from the left adjuster sleeve using the J36611.





18. Remove the pinion flange nut and the washer using the J8614-01,





19. Mount the left carrier case half and drive the pinion out of the carrier using the J33837-1 and the J33837-3.
20. Remove the pinion flange and the deflector.
21. Remove the pinion with the spacer, the bearing and the shim.
22. Remove the spacer from the pinion.





23. Remove the bearing from the pinion using the J22912-01 and a press.
24. Remove the shim.
25. Remove the outer pinion bearing, the cup, and the seal using the J33837-1, the J33837-3 and the J33837-6.
25.1. Insert the J33837-6 into the pinion bore.
25.2. Thread the forcing screw (J33837-3) into the J33837-6.
25.3. Turn the forcing screw in order to release the parts from the case.





26. Remove the inner bearing cup by pushing the inner bearing cup out using the J33837-1, the J33837-3 and the J33837-6.
27. Remove the differential pinion bolt and the shaft from the differential case.
28. Remove the differential pinion gears and the thrust washers.
29. Remove the side gears and the thrust washers. Mark the side gears and the case for reference during reinstallation.
30. Remove the ring gear mounting bolts.
31. Remove the ring gear. Do not pry between the ring gear and the case. Drive the gear off using a brass drift and a hammer.





32. Remove the side bearings using the J22888-20 and the J8107-2.





33. Remove the case bushings using the J33791-1 and the J33791-2.