Disassembly

Fig. 11 Removing pinion shaft:

Fig. 12 Removing drive pinion:

1. Remove axle assembly from vehicle, then axle shafts and carrier assembly.
2. Using a punch, mark bearing caps so they can be reinstalled in their original locations.
3. Remove nuts and bearing caps, then remove differential case and ring gear. Mark bearing races as to right or left so they can be reinstalled in their original locations.
4. Using suitable puller, remove differential side bearings. Record thickness of each shim pack and side bearing as it is removed and keep separated. These dimensions will be required during reassembly.
5. Remove ring gear bolts and separate ring gear from case. Use care when removing ring gear to avoid damaging differential case or ring gear. Do not force a chisel or other tools between joining surfaces.
6. Drive out pinion shaft lockpin using a drift. If necessary remove caulking in lockpin with a drill.
7. Remove pinion shaft using a drift, Fig. 11, then remove thrust block, pinion gears, side gears and thrust washers.
8. Remove pinion nut and companion flange. Do not discard nut as it will be required for bearing preload adjustment.
9. Drive pinion from carrier by placing a soft metal rod against end of drive pinion and striking rod with hammer, Fig. 12. The outer (front) bearing will fall into carrier, while the inner (rear) bearing will remain in the carrier bores.
10. Using an arbor press and tool J-22912, remove rear bearing from pinion.
11. Remove oil seal, then drive out outer races using a drift.