(S4WD)
Differential Carrier Assembly -Disassemble (S4WD)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
^ Tools Required
- J21551 Output Shaft Bearing Remover
- J222912-01 Pinion Bearing Remove
- J 23907 Slide Hammer
- J29369-1 Bushing/Bearing Remover
- J 29369-2 Bushing/Bearing Remover (2-3 inches)
- J33791 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 8614-01 Pinion Flange Holder
1. Remove the two remaining inner axle shaft housing bolts.
2. Remove the inner axle shaft housing with the inner axle shaft.
3. Remove the following components from the inner axle shaft housing:
3.1. The clutch cable retainer spring
3.2. The clutch fork assembly
3.3. The clutch fork inner spring
3.4. The clutch fork sleeve
3.5. The thrust washer
3.6. The clutch gear by doing the following:
3.6.1. Clamp the inner shaft housing in a vise. Clamp only on the mounting flange.
3.6.2. Strike the inside surface of the axle shaft with a hammer and a brass drift in order to dislodge the front drive axle clutch gear from the inner axle shaft.
3.6.3. Remove the front drive axle clutch gear.
3.7. Remove the thrust washer.
4. Remove the inner axle shaft.
5. Remove the clutch fork seal. Use a punch to drive out the seal.
6. Remove the inner axle shaft seal and the bearing by doing the following:
6.1. Install the J23907(1) and the J29369-1 (2) as shown.
6.2. Remove the inner axle shaft seal and the bearing by pulling on the J23907 (1).
7. Remove the front drive axle clutch shaft.
8. Remove the thrust washer from the right side differential carrier assembly case half.
9. Remove the clutch shaft bearing using the J34011.
10. Remove the inner axle shaft seal cover and the seal.
11. Remove the inner axle shaft seal by doing the following:
11.1. Install the inner axle shaft seal cover in a vise.
11.2. Install the J 29369-1 to the backside of the inner axle shaft seal.
11.3. Install the J23907 to the J29369-1.
11.4. Remove the inner axle shaft seal by pulling on the J23907
12. Remove the differential carrier assembly bolts.
13. 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.
14. Remove the differential case assembly.
15. Remove the differential bearing adjuster nut lock bolts and the differential bearing adjuster nut locks.
16. Remove the left differential bearing adjuster and the differential case bearing cup by doing the following:
16.1. Install the J 42213 onto the differential bearing adjuster nut.
16.2. Turn the J 42213 clockwise in order to remove the differential bearing adjuster and the differential case bearing cup out of the bore.
17. Remove the right differential bearing adjuster and the differential case bearing cup by doing the following:
17.1. Install the J 33792 onto the differential bearing adjuster nut.
17.2. Turn the J 33792 clockwise in order to remove the differential bearing adjuster and the differential case bearing cup out of the bore.
18. Remove the left inner shaft bearing using the J 36611 (2) and the J 8092 (1).
19. Remove the right inner shaft bearing using the d21551 (2) and the J8092 (1).
20. Install the J8614-01 as shown.
Remove the pinion nut while holding the J 8614-01.
21. Remove the washer.
22. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
23. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J8614-01 (1).
24. Remove the dust deflector from the pinion yoke by doing the following:
24.1. Tap the deflector off the pinion yoke.
24.2. Clean up the stake points on the pinion yoke.
25. Mount the left side differential carrier case in the J 33837-1.
26. Install the J 33837-3.
27. While holding the J 33837-3, turn the nut sleeve of the J 33837-1 counterclockwise to remove the following components:
^ The drive pinion
^ The drive pinion selectable shim
^ The inner pinion bearing
^ The collapsible spacer
28. Remove the collapsible spacer from the pinion.
29. 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.
30. Remove the pinion gear selectable shim.
31. Install the J 33837-6 (2) onto the J 33837-3 between the inner and the outer bearing cup.
32. While holding the J 33837-37 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
33. Install the J 33837-6 (2) onto the J 33837-3 on the inside surface of the outer bearing cup.
34. 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.
35. Install the J 33791 onto the differential carrier assembly bushings.
36. Remove the bushings using the J33791.