Overhaul

NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.





NOTE: There are two designs of wear washers.

Disassembly
1. Design with wear washer:
a. Press the two bevel gears and wear washers out of the differential housing by turning them.
b. Press together the differential pinions towards the center and check the differential shaft for score marks.
2. Design with needle bearing:
a. Tap out the locking pin.
b. Tap out the differential shaft.
c. Press out the bevel gears and needle bearings from the differential housing by turning them.
d. Check needle bearings and differential shaft for score marks.
3. Place the differential in a vice and undo the 10 screws.
The cylindrical gear wheel can now be removed from the differential.
Wrench size = 15 mm.
4. For dismantling bearings.





Assembly
1. Design with wear washer:
Install the two differential pinions into the differential housing so that the two shaft holes are exactly aligned.
2. Design with needle bearing:
a. Install the large pinions and associated needle bearings.
b. Install the two small pinions and associated needle bearings.
c. Install the differential shaft. Check that the hole for the locking pin is opposite the corresponding hole in the differential housing.
d. Install the locking pin.
3. Place the differential in a vice and install the crown wheel screws.
Wrench size = 15 mm.
Tightening torque: 77 Nm (56 ft. lbs.)
4. Place the entire differential in the gear case