Disassembly

DISASSEMBLY

To detect the real cause of trouble, inspect the following items before disassembling.

^ Tooth contact and backlash between hypoid driven gear and drive pinion
^ Hypoid driven gear runout on its back surface
^ Total preload of drive pinion

1) Set the ST on vise and install the differential assembly to ST.

ST 398217700 ATTACHMENT





2) Remove the oil drain plug and filler plug, and drain the gear oil.
3) Remove the air breather cap.

NOTE:
^ Do not attempt to replace the air breather cap unless necessary.
^ Whenever the air breather cap is removed, replace it with a new part.





4) Remove the bolts, and then remove the rear cover.
5) Keep the side retainers separate to make it possible to identify RH and LH sides. Remove the side retainer attachment bolts, set the ST to differential case, and extract the side retainers RH and LH with a puller.

NOTE:
Side retainer shim of each side should be kept together with its mating retainer.

ST 398457700 ATTACHMENT





6) Pull out the differential case assembly from the differential carrier.

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





7) When replacing the side bearing, remove the bearing cup from the side retainer using ST.

ST 398527700 PULLER ASSY





8) Remove the bearing cone with ST.

NOTE:
^ Do not attempt to disassemble the parts unless necessary.
^ Set the puller so that its claws catch the edge of the bearing cone.
^ Never mix up the RH and LH bearing races and cones.

ST 18759AA000 PULLER ASSY





9) Remove the hypoid driven gear by loosening hypoid driven gear bolts.





10) Drive out the pinion shaft lock pin from the hypoid driven gear side.

NOTE:
The lock pin is staked at the pin hole end on the differential carrier. Do not drive it out forcibly before removing the stake.

ST 899904100 STRAIGHT PIN REMOVER





11) Draw out the pinion mate shaft and remove pinion mate gears, side gears and thrust washers.

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





12) Remove the self-locking nut while holding the companion flange with ST.

ST 498427200 FLANGE WRENCH





13) Extract the companion flange with a puller.





14) Press the end of drive pinion shaft and extract it together with rear bearing cone, pinion height adjusting washer and washer.

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

ST 398467700 DRIFT





15) Remove the rear bearing cone from drive pinion by supporting the cone with ST.

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

ST 398517700 REPLACER





16) Remove the front oil seal from differential carrier using ST.

ST 398527700 PULLER ASSY





17) Remove the pilot bearing together with the front bearing cone and spacer using the ST.

ST 398467700 DRIFT





18) When replacing the bearings, use a brass bar to tap out the front bearing cup and rear bearing cup (in this order).