Disassembly

DIFFERENTIAL ASSEMBLY


Disassembly

1. Drain gear oil, if necessary.
2. Remove side flanges.
3. Remove rear cover mounting bolts.





4. Remove rear cover to insert the seal cutter (A) [SST:
KV10111100 (J-37228)] between gear carrier and rear cover.

CAUTION:
- Never damage the mating surface.
- Never insert flat-bladed screwdriver, this may damage the mating surface.





5. Using two spacers, mount carrier on the attachment (A) [SST:
KV38100800 (J-25604-01)].





6. For proper reinstallation, paint matching marks on one side of the bearing cap.

CAUTION:
- For matching marks, use paint. Never damage bearing caps and gear carrier.
- Bearing caps are manufactured as integral molding. Use the matching marks to them in their original positions.





7. Remove bearing caps.





8. Lift differential case assembly out with a suitable tool.





- Keep side bearing outer races together with inner race. Never mix them up.
Also, keep side bearing adjusting washers together with bearings.
















CAUTION:
- To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
- It is not necessary to remove side bearing inner race except when it is replaced.





10. For proper reinstallation, paint matching marks on one differential case assembly.

CAUTION:
For matching marks, use paint. Never damage differential case and drive gear.
11. Remove drive gear mounting bolts.
12. Tap drive gear off differential case assembly with a soft hammer.

CAUTION:
Tap evenly all around to keep drive gear from bending.





13. Put matching marks with paint.





14. Loosen screws on differential cases A and B.





15. Separate differential case A and B, then remove viscous coupling, pinion mate gear, pinion mate thrust washer, side gear, pinion mate shaft, circular clip and side gear thrust washer from differential cases.
16. Remove side oil seal, using a suitable tool.

CAUTION:
Never damage gear carrier.