Differential: Service and Repair

DISASSEMBLE

Differential Bearing Removal:

1. Remove left and right differential bearings using tools shown in the Differential Bearing Removal image, or equivalent.
2. Remove speedometer drive gear, then the differential side gears by rotating gears toward case window.
3. Drive out pinion shaft retaining pin using a 5/32 inch punch.
4. Remove pinion shaft, pinion gears, and thrust washer.
5. If inspection indicates a need for final drive gear replacement, proceed as follows:

Drive Gear Rivet Removal:

a. Remove rivets using a 5/16 inch drill, avoiding distortion of case by drilling only the preformed side of the rivets.
b. After drilling, remove head of the rivet using a chisel.
c. Using a punch, drive out the remaining shank.

ASSEMBLE
1. Lubricate thrust washer, thrust surfaces on gears, and differential case with automatic transaxle fluid.
2. If removed, align and press final drive gear onto the differential case.

Drive Gear Attaching Bolt Installation:

3. Install gear attaching bolts as shown in the Drive Gear Attaching Bolt Installation image.
4. Use only nuts and bolts supplied for service and tighten.
5. Install speedometer drive gear, ensuring gear is installed with bevel on the inside diameter facing the differential case.

Differential Ball Bearing Installation:

6. Install differential ball bearing using differential bearing installation tool No. T83P-4220-BH or equivalent.