Disassembly

DISASSEMBLY
Side Flange
1. Drain the differential gear oil if necessary.
2. Remove the side flange using Tools.
Tool numbers
A: KV40104100 ( - )
B: ST36230000 (J-25840-A)
3. Remove the side oil seal using suitable tool.

CAUTION: Do not to damage gear carrier.

Differential Assembly
1. Remove the side flanges.
2. Remove the carrier cover bolts.





3. Remove the carrier cover bolts and separate the carrier cover from the gear carrier using Tool.
Tool number: KV10111100 (J-37228)

CAUTION:
^ Do not damage the mating surface.
^ Do not insert flat-bladed screwdriver, this will damage the mating surface.





4. Mount the carrier on the Tool using two 45 mm (1.77 in) spacers.
Tool number: KV38100800 (J-25604-01)





5. For proper reinstallation, paint matching marks on one side of the side bearing cap and gear carrier.

CAUTION:
^ For matching marks, use paint. Do not damage side bearing cap or gear carrier.
^ Side bearing caps are line-board during manufacture. The matching marks are used to reinstall them in their original positions.





6. Remove the side bearing caps.





7. Lift the differential case assembly out using Tool.
Tool number: HT72400000 ( - )





CAUTION:
^ Keep side bearing outer races together with inner race. Do not mix them up.
^ Keep side bearing adjusting washers together with side bearings.





8. Remove the side bearing inner races using Tools.
Tool number
A: ST3306S001 ( - )
B: ST33061000 (J-8107-2)

CAUTION:
^ Engage Tool jaws in bearing groove to prevent damage.
^ Place copper plates between the side bearing and drive gear and the vise to prevent damage.
^ Do not remove side bearing inner race unless it is being replaced.





9. For proper reinstallation, paint matching marks on the differential case and drive gear.

CAUTION: Use paint for matching marks. Do not damage differential case or drive gear.

10. Remove the drive gear bolts.
11. Tap the drive gear off the differential case using suitable tool.

CAUTION: Tap evenly all around to keep drive gear from bending.





12. Remove the lock pin of the pinion mate shaft from the drive gear side using suitable tool.





13. Remove the pinion mate shaft.





14. Turn the pinion mate gear, then remove the pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from the differential case.

Drive Pinion Assembly
1. Remove the differential assembly.





2. Remove the drive pinion lock nut using Tool.
Tool number: KV40104000 ( - )
3. Put matching marks on the companion flange and drive pinion using paint.

CAUTION: Use paint to make the matching marks. Do not damage the companion flange or drive pinion.





4. Remove the companion flange using suitable tool.





5. Press the drive pinion assembly (with rear inner bearing race and collapsible spacer) out of the gear carrier.

CAUTION: Do not drop drive pinion assembly.

6. Remove the front oil seal.

CAUTION: Do not damage gear carrier.

7. Remove the drive pinion front bearing inner race.





8. Remove the drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool.
Tool number: ST30021000 ( - )





9. Remove the drive pinion front and rear bearing outer races by tapping them uniformly using suitable tool.

CAUTION: Do not damage gear carrier.