Disassembly

Side Shaft Assembly





1. Hold extension tube retainer with puller, then press out side shaft using a press.





2. Remove side shaft oil seal (1) from extension tube retainer with a flat-blade screwdriver.

CAUTION: Be careful not to damage extension tube retainer.

3. Remove side shaft bearing from extension tube retainer.
4. Remove O-ring from extension tube retainer.
5. Remove dust sealed from side shaft.

Differential Assembly
1. Drain gear oil.
2. Remove carrier cover mounting bolts.





3. Remove carrier cover to insert the seal cutter between gear carrier and carrier cover.
Tool number A: KV10111100 (J-37228)

CAUTION:
^ Be careful not to damage the mating surface.
^ Never insert flat-bladed screwdriver, this way damage the mating surface.





4. Remove side retainer.
5. Remove side bearing adjusting shim.
6. Remove O-ring from side retainer.





7. Remove differential case assembly from gear carrier.





8. Remove side oil seal (right side) from side retainer.





9. Remove side bearing outer race with puller.
Tool number A: KV381054S0 (J-34286)
10. Remove O-ring from gear carrier.
11. Remove side oil seal (left side) from gear carrier.





12. Remove side bearing outer race with puller.
Tool number A: KV381054S0 (J-34286)





13. Remove side bearing inner race.
To prevent damage to bearing, engage puller jaws in groove (<---).
Tool number
A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)

CAUTION:
^ To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
^ It is not necessary to remove side bearing inner race except it is replaced.





14. For proper reinstallation, paint matching marks on one differential case assembly.

CAUTION: For matching marks, use paint. Never damage differential case and drive gear.

15. Remove drive gear mounting bolts.
16. Tap drive gear off differential case assembly with a soft hammer.

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





17. Remove lock pin of pinion mate shaft with a punch from drive gear side.





18. Remove pinion mate shaft.





19. Turn pinion mate gear, then remove pinion mate gears, pinion mate thrust washers, side gears and side gear thrust washers from differential case.

Drive Pinion Assembly
1. Remove differential assembly. Refer to "Differential Assembly".





2. Remove drive pinion lock nut with a flange wrench.





3. Put matching mark (B) on the end of drive pinion. The matching mark should be in line with the matching mark (A) on companion flange (1).

CAUTION: For matching mark, use paint. Never damage companion flange and drive pinion.

NOTE: The matching mark (A) on the final drive companion flange (1) indicates the maximum vertical runout position. When replacing companion flange, matching mark is not necessary.





4. Remove companion flange using the suitable puller.





5. Press drive pinion assembly out of gear carrier.

CAUTION: Never drop drive pinion assembly.

6. Remove front oil seal.
7. Remove pinion front bearing inner race.
8. Remove drive pinion bearing adjusting washer and drive pinion adjusting washer.





9. Remove pinion rear bearing inner race and pinion height adjusting washer with replacer.
Tool number A: ST30031000 (J-22912-01)





10. Tap pinion front/rear bearing outer races uniformly a brass rod or equivalent to removed.

CAUTION: Be careful not to damage gear carrier.