Disassembly

To detect real cause of trouble, inspect the following items before disassembling.
- Tooth contact of crown gear and pinion, and backlash
- Runout of crown gear at its back surface
- Turning resistance of drive pinion





1. Set ST on vise and install the differential assembly to Special Tool (ST).
ST 398217700 ATTACHMENT, or equivalent.
2. Drain gear oil by removing plug.





3. Remove the air breather cap.

NOTE: Do not attempt to replace the air breather cap unless necessary.





4. Remove rear cover by loosening retaining bolts.





5. Make right and left side bearing retainers in order to identify them at reassembly. Remove side bearing retainer attaching bolts, set ST to differential case, and extract right and left side bearing retainers with a puller.
ST 398457700 ATTACHMENT, or equivalent.

CAUTION: Each shim, which is installed to adjust the side bearing preload, should be kept together with its mating retainer.





6. Pull out differential assembly from differential carrier.

CAUTION: Be careful not to hit the teeth against the case.





7. When replacing side bearing, pull bearing cup from side bearing retainer using ST.
ST 398527700 PULLER ASSY or equivalent.





8. Extract bearing cone with ST.
ST 399527700 PULLER SET, or equivalent.

CAUTION: Do not attempt to disassemble the parts unless necessary.

NOTE:
- Set puller so that its claw catch the edge of the bearing cone.
- Never mix up the right and left hand bearing cups and cones.





9. Remove crown gear by loosening crown gear bolts.

CAUTION: Further disassembling is not allowed.





10. Drive out pinion shaft lock pin from crown gear side.
ST 899904100 STRAIGHT PIN REMOVER or equivalent.

NOTE: The lock pin is staked at the pin hole end on the differential carrier; do not drive it out forcibly before unstaking it.





11. Hold companion flange with ST and remove drive pinion nut.
ST 498427200 FLANGE WRENCH or equivalent.





12. Extract the companion flange with a puller.





13. Press the end of drive pinion shaft and extract it together with rear bearing cone, preload adjusting spacer and washer.
ST 398467700 DRIFT or equivalent.

NOTE: Hold the drive pinion so as not to drop it.





14. Draw out pinion mate shaft and remove pinion mate gears, side gears and thrust washers.

NOTE: The gears as well as thrust washers should be marked or kept separated left and right, and front and rear.





15. Hold companion flange with ST and remove drive pinion nut.
ST 498427200 FLANGE WRENCH or equivalent.





16. Extract the companion flange with a puller.





17. Press the end of drive pinion shaft and extract it together with rear bearing cone, preload adjusting spacer and washer.
ST 398467700 DRIFT or equivalent.

NOTE: Hold the drive pinion so as not to drop it.





18. Remove rear bearing cone from drive pinion by supporting cone with ST.
ST 498515500 REPLACER or equivalent.

NOTE: Place the replacer so that its center-recessed side faces the pinion gear.





19. Remove front oil seal from differential carrier using ST.
ST 398527700 PULLER ASSY or equivalent.





20. Remove pilot bearing together with front bearing cone using ST.
ST398467700 DRIFT or equivalent.





21. When replacing bearings, tap front bearing cup and rear bearing cup in this order out of case by using a brass bar.