Disassemble

Dismantling

Ensure that all lubricant is drained from the unit and support the unit in a vice.

Fig.30:

Remove the ten 1/2 in. AF rear cover securing bolts (1, Fig.30). the cover and the gasket. Remove the locking wire and five 5/8 in. AF bolts securing the caliper mounting bracket on one side and withdraw the output shaft assembly.

Fig.31:

Repeat for the shaft on the other side. Remove the two 3/4 in. AF bolts (1, Fig.31) securing the differential bearing cap, lift out the cap from the differential housing, repeat for the other side.

Using two suitably padded levers, pry out the differential unit.

Fig.32:

Using tool 18G 1205 (1, Fig.32) to hold the drive flange. remove the pinion nut and washer and withdraw the flange (2, Fig.32)

Using a suitable press extract the pinion from the housing.

Using tool 18G 134 remove the oil seal, oil thrower and outer bearing cone.

Examine the inner and outer bearing cups for wear, if replacement is required extract the outer cup using tools 18G 134 and SL550/1 for inner bearing removal, carefully tap the bearing cone out with a brass punch in the cut-outs provided in the differential casing and carefully collect the shims.

Fig.33:

Remove the pinion head bearing using tools 47 (1, Fig.33). SL47-1/1 (2, Fig.33).

Fig.34:

Remove the differential side bearings using tool Nos. 47 (1, Fig.34). SL 14-3/2 (2, Fig.34) and SL 14-3/1 (3, Fig.34), and collect the shims.

Powr-Lok Only

Fig.35:

In the absence of any alignment marks (1, Fig.35), scribe a line across both halves of differential casing to facilitate reassembly.

Fig.36:

Remove the ten 11/16 in. AF crown wheel bolts (1, Fig.36) and remove the crown wheel (2, Fig.36).

Fig.37:

Remove the eight 9/16 in. AF bolts (1, Fig.37). securing both halves of the differential casing (2, Fig.37).

Remove differential side ring (3, Fig.37). Remove pinion side gear and pinion cross-shafts complete with gears (4, Fig.37). Separate cross-shafts (5, Fig. 37).

Remove remaining side gear (6, Fig.37) and ring (7, Fig.37).

Extract the remaining clutch discs (8, Fig.37) and plates (9, Fig.37).