Disassembly

Fig. 22 Exploded View Of Differential:

Refer to Fig. 22 for differential component locations, when performing the following procedure.
1. Place differential in overhaul stand and remove differential cover.

Fig. 23 Removing Side Gear Shaft:

Fig. 24 Removing Side Gear Shaft Oil Seals:

2. Using special service tool No. 09520-24010, or equivalent, remove side gear shafts, Fig. 23.
3. Using special service tool No. 09380-00010, or equivalent, remove oil seals, Fig. 24.
4. Remove eight bolts and differential carrier retainer.

Fig. 25 Removing Carrier Retainer:

5. Using special service tool No. 09950-20017, or equivalent, remove carrier retainer, Fig. 25.
6. Remove differential case from carrier.
7. Using a screwdriver, remove O-ring from differential carrier retainer.

Fig. 26 Removing Side Bearing Outer Race & Plate Washer:

8. Using a press and special service tools Nos. 09608-06020 and 09608-06110 or equivalents, press out outer races and washers, Fig. 26.
9. Using a hammer and chisel, loosen staked part of companion flange nut.

Fig. 9 Pinion Flange Removal:

10. Using special service tools Nos. 09229-55010 and 09330-00021 or equivalents remove companion flange nut, Fig. 9.
11. Press out drive pinion and bearing from pinion flange and bearing.
12. Remove spacer from drive pinion.

Fig. 27 Removing Pinion Oil Seal:

13. Using special service tool No. 09308-00010 or equivalent, remove oil seal, Fig. 27.
14. Remove oil slinger and front bearing.

Fig. 28 Removing Rear Bearing From Drive Pinion:

15. Using a press and special service tool No. 09950-00020 or equivalent, remove rear bearing from drive pinion, Fig. 28.
16. Using a brass bar and a hammer, drive out outer races and adjusting washer from differential carrier. Measure adjusting washer and note thickness for reassembly.
17. Using a screwdriver, remove snap rings from side gear shaft.

Fig. 10 Side Bearing Removal:

18. Using special service tool No. 09950-20017 or equivalent, remove side bearings from differential case, Fig. 10.
19. Place alignment marks on ring gear and carrier, then remove ten set bolts. Tap ring gear off carrier using a plastic hammer.
20. Using a hammer and punch, drive out differential straight pin, then remove the following parts from differential:
a. Pinion shaft.
b. Two pinions and thrust washers.
c. Two side gears and thrust washers.

Fig. 29 Removing Companion Flange Dust Deflector:

Fig. 30 Installing Companion Flange Dust Deflector:

21. Replace pinion flange dust deflector as follows:
a. Using a press and special service tools Nos. 09608-35014 and 09950-00020 or equivalents, remove dust deflector, Fig. 29.
b. Using a press and special service tool No. 09316-60010 or equivalent, press on new dust deflector, Fig. 30.

Fig. 31 Removing Side Gear Shaft Dust Cover:

Fig. 32 Installing New Side Gear Shaft Dust Cover:

22. Replace side gear dust covers as follows:
a. Using a press and special service tool No. 09950-00020 or equivalent, remove dust cover, Fig. 31.
b. Using a press and special service tools Nos. 09502-24010 and 09608-35014 or equivalents, install new dust cover, Fig. 32. If it does not set flat, tap down with screwdriver.