Disassembly

Fig. 3 Exploded View Of Differential:

For disassembly and assembly procedures, refer to Fig. 3 for differential component locations.
1. Place differential in overhaul stand and remove differential cover.
2. Remove side gear shaft snap rings, then using slide hammer tool No. 09910-00015, or equivalent, remove side gear shafts.
3. Using screwdriver and hammer, remove side oil seals.

Fig. 4 Removing Snap Ring On Drive Pinion Side:

Fig. 5 Dial Indicator Placement For Spreading Housing:

4. Place special service tool No. 09571-50010, or equivalent, on differential, Fig. 4.
5. Install dial indicator on carrier, Fig. 5.
6. Tighten bolt on special service tool, to spread differential carrier to make room for snap ring removal. Pay attention to dial indicator, do not spread more than 0.008 inch.
7. Using snap ring pliers No. 09905-00030, or equivalent, remove drive pinion side snap ring. Measure snap ring thickness and note for assembly.
8. Remove dial indicator and loosen special service tool bolt but do not remove.

Fig. 6 Snap Ring Removal:

9. Using bearing race tool No. 09550-10012, or equivalent and a hammer, tap on side bearing outer race on ring gear side of differential three or four times, Fig 6.
10. Using snap ring pliers No. 09905-00030, or equivalent, remove snap ring on ring gear side of differential. Measure thickness and note for assembly.
11. Tighten special service tool bolt, forcing out bearing race on ring gear side.

Fig. 7 Match Carrier To Housing:

Fig. 8 Bearing Race Removal:

12. Turn opening in differential case to opening in differential carrier, Fig. 7.
13. Align outer race with indentation in carrier, Fig. 8.
14. While lifting up on ring gear side of differential, slowly slide race over top of gear set. Tag all snap rings and races left or right.
15. Lift ring gear side of differential and remove from housing.
16. Using a hammer and chisel, remove staked part of pinion flange nut.

Fig. 9 Pinion Flange Removal:

17. Using pinion nut removal tools Nos. 09229-55010 and 09330-00021, or equivalent, remove pinion nut, Fig. 9.
18. Press out drive pinion and bearing from pinion flange and bearing.
19. Remove pinion oil seal.
20. Remove oil slinger and bearing. Use removal tool No. 09950-00020, or equivalent and press bearing from drive pinion.
21. Use a brass bar and hammer and remove pinion races and adjusting washer. Only remove these if replacing pinion bearings.

Fig. 10 Side Bearing Removal:

22. Using bearing removal tool No. 09950-20017, or equivalent, remove side bearings, Fig. 10.
23. Place alignment marks on ring gear and carrier, then remove ten set bolts. Tap off ring gear with plastic hammer.
24. Using a hammer and punch to 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.
25. Replace pinion flange dust deflector as follows:
a. Using deflector removal tool No. 09550-10012, or equivalent, press off deflector.
b. Using deflector installer No. 09316-60010, or equivalent, press on new deflector.
26. Replace side gear dust covers as follows:
a. Using dust cover removal tool No. 09950-00020, or equivalent, press off dust cover.
b. Using dust cover installer No. 09316-20011, or equivalent, press on new dust cover. If it does not set flat, tap down with screwdriver.