Disassembly

1. Remove the output shafts with two pry bars as shown above.






2. Strike the differential carrier with a plastic hammer to separate it from the case.

Caution: Be careful not to strike the aluminum alloy differential case.






3. Mount the differential gear assembly on SST #49 M005 561 and #49 0107 680A as shown.
4. Remove the lock plates.
5. Mark one bearing cap and carrier, then remove the bearing caps.
6. Mark one adjusting nut and carrier, then remove the adjusting nuts.






7. Using protective plates, secure the gear case in a vise and remove the knock pin by tapping out toward the ring gear side as shown above.






8. Place match marks on the side bearings so they can be reinstalled in the same position.
9. Using SST #49 0839 425C as shown above, remove the bearing inner races (side bearings) from the gear case.
10. Remove the gear case.
11. Remove the ring gear.
12. Remove the side bearing inner races, pinion shaft, thrust washers, and side gears.
13. Inspect the ring gear for wear and cracks, inspect the pinion gears individual gear teeth for wear and cracks, inspect the side gears for wear and cracks.






14. Hold the companion flange with SST #49 S210 710 or equivalent spanner wrench and remove the locknut.






15. Pull the companion flange off with SST #49 0839 425C as shown above.






16. Attach a miscellaneous locknut to the drive pinion and carefully tap it out using a copper hammer as shown above.
17. Inspect the companion flange splines for signs of wear and damage.
18. Inspect drive pinion splines for signs of wear and damage, inspect the individual gear teeth for wear and cracks.
19. Remove the spacer.






20. Using the two grooves in the carrier, alternately tap out the bearing outer races as shown.






21. Using SST #49 0636 145, remove the rear bearing inner race as shown.

Note: Support the drive pinion by hand so that it does not fall.

22. Remove the collapsible spacer.
23. Inspect all bearings for damage or rough rotation.
24. Remove and inspect the differential carrier and final gear set.
25. Remove the output shaft oil seal, baffle, and breather.






26. Drill holes around the differential mounting rubber.






27. Hit the edge of the differential mounting rubber to remove it.
28. Replace any parts that show damage, cracking, or excessive wear.