(A4WD)

Differential Carrier Assembly -Disassemble (A4WD)

^ Tools Required
- J21551 Output Shaft Bearing Remover
- J22912-O1 Pinion Bearing Remover
- J 23907 Slide Hammer
- J29369-1 Bushing/Bearing Remover
- J 33791 Bushing Remover and Installer Set
- J 33792 Side Bearing Adjuster Socket
- J 33837 Pinion Bearing Cup Remover and Installer
- J 36611 Output Shaft Bearing Remover
- J 42213 Side Bearing Adjuster Socket
- J 8092 Driver Handle
- J 8614-O1 Pinion Flange Holder

Inspection Procedure
Perform the following before disassembling the axle:
1. Remove the drain plug from the axle.
2. Drain the axle lubricant.
3. Inspect the oil and the case for metal chips.
Determine the source of the metal chips, such as a broken gear or bearing cage.
4. Check the ring gear backlash.
This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and preloading the differential case.
Determine the cause of the axle problem before disassembly, if possible.

Disassembly Procedure
1. Remove the inner axle shaft from the inner axle shaft housing.
2. Remove the inner axle shaft housing from the differential carrier assembly.
3. Remove the inner axle shaft seal and the bearing by doing the following:





3.1. Install the J23907 (1) and the J 29369-2 (2) as shown.
3.2. Remove the inner axle shaft seal and the bearing by pulling on the J23907 (1).
4. Remove the left inner axle shaft.
5. Remove the inner axle shaft seal cover and the seal.
6. Remove the inner axle shaft seal by doing the following:
6.1. Install the inner axle shaft seal cover in a vise.
6.2. Install the J29369-1 to the backside of the inner axle shaft seal.
6.3. Install the J23907 to the J29369-1.
6.4. Remove the inner axle shaft seal by pulling on the J 23907.
7. Remove the differential carrier assembly bolts.





8. Separate the left carrier case half from the right carrier case half by inserting a screwdriver into the slots provided and prying the case apart.
9. Remove the differential case assembly.





10. Remove the differential bearing adjuster nut lock bolts and the differential bearing adjuster nut locks.





11. Remove the left differential bearing adjuster and the differential case bearing cup by doing the following:
11.1. Install the J 42213 onto the differential bearing adjuster nut.
11.2. Turn the J 42213 clockwise in order to remove the differential bearing adjuster and the differential case bearing cup out of the bore.





12. Remove the right differential bearing adjuster and the differential case bearing cup by doing the following:
12.1. Install the J 33792 onto the differential bearing adjuster nut.
12.2. Turn the J 33792 clockwise in order to remove the differential bearing adjuster and the differential case bearing cup out of the bore.





13. Remove the left inner axle shaft bearing using the J36611 (2) and the J8092 (1).





14. Remove the right inner shaft bearing using the J 21551 (2) and the J 8092 (1).





15. Install the J8614-01 as shown.
Remove the pinion nut while holding the J 8614-01.
16. Remove the washer.





17. Install the J 8614-2 (2) and the J8614-3 (3) into the J8614-01 (1) as shown.
18. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J8614-01 (1).
19. Remove the dust deflector from the pinion yoke by doing the following:
19.1. Tap the deflector off the pinion yoke.
19.2. Clean up the stake points on the pinion yoke.





20. Mount the left side differential carrier case in the J 33837-1.
21. Install the J 33837-3.
22. While holding the J 33837-3, turn the nut sleeve of the J 33837-3 counterclockwise to remove the following components:
^ The drive pinion
^ The drive pinion selectable shim
^ The inner pinion bearing
^ The collapsible spacer
23. Remove the collapsible spacer from the pinion.





24. Remove the inner pinion bearing by installing the J22912-01 between the pinion bearing and the pinion gear and pressing the bearing off the pinion.
25. Remove the pinion gear selectable shim.





26. Install the J 33837-6 (2) onto the J 33837-3 between the inner and the outer pinion bearing cup.
27. While holding the J 33837-3, turn the nut sleeve of the J 33837-1 clockwise in order to remove the following components:
^ The pinion oil seal
^ The pinion outer bearing
^ The pinion outer bearing cup
28. Install the J 33837-6 (2) onto the J 33837-3 on the inside surface of the outer bearing cup.
29. While holding the J 33837-3, turn the nut sleeve of the J 33837-1 counterclockwise in order to press the inner pinion bearing cup out from the differential carrier case.





30. Install the J33791 onto the differential carrier assembly bushings.
31. Remove the bushings using the J33791.