Front

Disassemble in the order shown in the illustration, referring to the following notes:





Differential Casing (1)
1. Mount the differential casing on the Special Service Tools (SST).





2. Install the SST.
3. Attach a dial indicator to the SST.
4. Spread the differential casing.

NOTE: Do not spread the differential casing over 0.25 mm (0.010 inch).





Bearing Caps (2)
^ Make a note of the matching letters on the bearing caps and on the differential casing.

Differential Gear Assembly (3)
1. Remove the differential gear assembly.

CAUTION: Do not damage the machined surfaces.

NOTE: It may be necessary to pry the differential gear assembly out of the casing.

2. Remove the SST.

Bearing Cup (4)

NOTE:
^ SST number: 49 UN01 026 Differential Housing Spreader

^ Tag the bearing cup locations for installation.

Companion Flange (5)
1. Hold the companion flange with the SST and remove the locknut and washer.

NOTE: SST number: 49 S120 710 Companion Flange Holder

2. Remove the companion flange using Companion Flange Remover T77F-4220-B1, or equivalent.
3. Remove the dust shield.

Drive Pinion, Oil Slinger/Selective Shim And Inner Bearing (6)
^ Remove the drive pinion, oil slinger/selective shim and inner bearing using a plastic hammer.

WARNING: Use care when handling the drive pinion, as the gear teeth may be sharp.

CAUTION: Catch the drive pinion to prevent damage to the teeth.





Oil Seal (7)
^ Remove the oil seal using the SSTs and Seal Remover TOOL-1175-AC, or equivalent.





Bearing Inner Race (11)
^ Remove the bearing inner race using the SST and Pinion Bearing Cup Remover T86T-4628-AH or equivalent. Insert the tools from the front of the differential casing, as shown in the illustration.

Oil Baffle (12)
^ Remove and replace the oil baffle with an oil baffle of equal thickness. If an equal thickness baffle is not available, use selective shims to compensate for the difference.





Bearing Outer Race (13)
^ Remove the bearing outer race using the SST and Pinion Bearing Cup Remover T86T-4628-BH, or equivalent. Insert the tools from the rear of the differential casing, as shown in the illustration.

Side Bearing (14)
1. Remove the side bearings using a press and Bearing Pulling Attachment D84L-1123-A, or equivalent.
2. Match the side bearing with the bearing cup removed from the same side.

NOTE: It is recommended that the side bearings be replaced.

Shims (16)
^ Remove and tag the shims for location during installation.

NOTE:
^ Inspect for bent shims or deep grooves.

^ The shims will be reused during assembly unless they are damaged. Replace any damaged shims.





Pinion Shaft (18)
1. Drive the lockpin out of the gear case.





2. Drive the pinion shaft out of the gear case.





Pinion Gear And Thrust Washer (19)
^ Rotate the pinion gears and thrust washers to the gear case opening and remove them.

Rear Bearing (22)
^ Remove the rear bearing using a press and Bearing Pulling Attachment D84L-1123-A, or equivalent.

NOTE: Be careful not to damage the oil slinger/selective shim while removing the rear bearing.