Disassembly

Special Tools:

CAUTION: Many components and surfaces in the axle are precision machined. Careful handling during disassembly, cleaning, inspection, and assembly will prevent unnecessary damage to machined surfaces.

1. Remove the front drive axle assembly from the vehicle.

2. Attach the axle assembly to the special tool.

3. Note: Place a suitable drain pan under the axle.

Remove the differential housing cover.
1. Remove the bolts.
2. Remove the differential housing cover.
4. Drain the axle lubricant from the differential housing.

5. Remove the axle shaft using a jerking motion.

6. Using the special tool and a suitable impact slide hammer, remove the axle shaft oil seal.

7. Using the special tool and a suitable impact slide hammer, remove the axle shaft bearing.

8. Using the special tool and a suitable impact slide hammer, remove the axle shaft oil seal.

9. Using the special tool and a suitable impact slide hammer, remove the axle tube bearing.

10. CAUTION: The matched numbers or letters stamped on both of the differential bearing caps and the differential housing must correspond during assembly.

Remove the differential bearing caps.
1. Remove the bolts.
2. Remove the differential bearing caps.

11. CAUTION: The Housing Spreader Adapter bolts have a minimum thread engagement as specified.

Install the special tool.

12. Install the special tools.
- Position the Clutch Housing Alignment Adapter needle in the Housing Spreader Adapter hole.

13. CAUTION: Over spreading can damage the differential housing.

Spread the differential housing to the specification.
1. Adjust the special tool to zero.
2. Tighten the Differential Carrier Spreader screw to spread the differential housing to the specification.
3. Remove the Dial Indicator with Bracketry and the Clutch Housing Alignment Adapter.

14. CAUTION: Use wood blocks to avoid damaging the differential housing.

Remove the differential assembly from the differential housing.
1. Position the wood blocks.
2. Push downward on the pry bars.
3. Remove the differential assembly.
4. Remove the special tool.

15. Measure the pinion bearing preload.
- Using a Nm (pound-inch) torque wrench, measure the torque required to maintain pinion rotation. Record the measurement.

16. Index-mark the pinion flange and the pinion stem.

17. Use the special tool to hold the flange while removing the nut.

18. Using the special tool, remove the pinion flange.

19. WARNING: The gear teeth have sharp edges. Handle the gear with care to avoid personal injury.

CAUTION: Never use a metal hammer on the pinion. Use a soft mallet to drive the pinion out of the differential housing.

Using a soft-face hammer, remove the pinion from the differential housing.
1. Hold the pinion inside the differential housing.
2. Use a soft-face hammer to remove the pinion from the differential housing.

20. Using the special tool and a suitable impact slide hammer, remove the pinion seal.

21. Remove the front axle drive pinion shaft oil slinger and the differential pinion bearing.

22. Remove the outer differential drive pinion bearing cup by tapping alternately on each side of the cup to prevent it from cocking in the bore.

23. Remove the inner differential drive pinion bearing cup by tapping alternately on each side of the cup to prevent it from cocking in the bore.

24. Using the special tool and a suitable press, remove the differential pinion bearing.

25. Remove the pinion position shim from the differential pinion gear. Measure the pinion position shim thickness with a micrometer. Record the measurement.
26. Remove the differential ring gear, the differential bearings, and if necessary, disassemble the differential case.