Disassembly

Differential Assembly
1. Drain gear oil, if necessary.
2. Remove side flange.
3. Remove rear cover mounting bolts.





4. Remove rear cover to insert the seal cutter between gear carrier and rear 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.





5. Using two 45 mm (1.77 in) spacers, mount carrier on the attachment.
Tool number A: KV38100800 (J-25604-01)





6. For proper reinstallation, paint matching marks on one side of the bearing cap.

CAUTION:
^ For matching marks, use paint. Never damage bearing caps and gear carrier.
^ Bearing caps are line-board during manufacture. The matching marks are used to reinstall them in their original positions.





7. Remove bearing caps.





8. Lift differential case assembly out with a suitable tool.





^ Keep side bearing outer races together with inner race. Do not mix them up. Also, keep side bearing adjusting washers together with bearings.





9. 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.





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

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

11. Remove drive gear mounting bolts.
12. Tap drive gear off differential case assembly with a soft hammer.

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





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





14. Remove pinion mate shaft.





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

Drive Pinion Assembly
1. Remove differential assembly.





2. Remove drive pinion lock nut with the 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 side oil seal.
8. Remove pinion front bearing inner race.
9. Remove collapsible spacer.





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





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

CAUTION: Be careful not to damage gear carrier.