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 SET





2) Remove the oil drain plug and oil temperature switch, and drain the gear oil.

NOTE:
Remove the oil temperature switch and adapter as a unit.

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 hypoid driven gear teeth against the case.





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

NOTE:
Do not disassemble the differential case assembly.





10) Remove the self-locking nut while holding the companion flange with ST.
ST 18633AA000 WRENCH COMPL





11) Extract the companion flange with a puller.





12) 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





13) Remove the rear bearing cone from the drive pinion.

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

ST 398517700 REPLACER





14) Remove the front oil seal from differential carrier using ST.
ST 398527700 PULLER ASSY





15) Remove the pilot bearing together with the front bearing cone and spacer using the ST.
ST 398467700 DRIFT





16) When replacing the bearings, hit out the front bearing cup and rear bearing cup in this order from outside the case by using a brass bar.