Disassembling Unit

DISASSEMBLING UNIT








1. Hold differential assembly securely and put identification marks on differential side bearing caps (6).
2. Take off differential side bearing lock plates (4) and differential side bearing caps (6) by removing their bolts and then take out bearing adjusters (5), side bearing outer races and drive bevel gear with differential case.





3. For 2 differential pinion type, remove differential side gear, pinion gear and pinion shaft.
a. With aluminum plates (4) placed on vise first, grip differential case with it and remove bevel gear (3) by removing its bolts (1).
b. Remove differential left case (2) from differential right case.





c. Drive out spring pin with special tool and hammer and disassemble differential side gears, pinions, washers and shaft in differential case (1).
Special tool (A): 09922-85811
4. For 4 differential pinion type, remove drive bevel gear, pinion gear and pinion shaft.





a. Remove bevel gear by removing its bolts in the same manner as step a) of 2 differential pinion type (Step 3).
b. There are 8 bolts fastening two differential case halves together. Remove these bolts to sever right-hand case half from left-hand one, and take off right-hand one.
Special tool (B): 09930-40113





c. Remove pinion shaft, side gears, washers, differential pinions, spring washers, thrust washers.





5. Using special tools, pull out differential side bearings (1).
Special tool
(C): 09913-85230
(D): 09913-61510
6. Remove bevel pinion assembly.








a. Hold universal joint flange with special tool and then remove flange nut by using power wrench (4 - 10 magnification) (2).
Special tool (E): 09922-66020





b. Make mating marks (1) on drive bevel pinion and companion flange.

CAUTION: Don't make mating mark on the coupling surface of the flange.

c. Remove companion flange from pinion. Use special tool if it is hard to remove.
Special tool (F): 09913-65135





d. Remove bevel pinion with rear bearing, shim and spacer from carrier.
If it is hard to remove, screw an used nut into pinion and hammer on that nut with a plastic hammer but never directly on pinion.








e. Remove bevel pinion rear bearing (2) by using bearing puller (3) and press.





7. Using a hammer and brass bar (1), drive out front bearing outer race with bearing (2) and oil seal (3).





8. Drive out rear bearing outer race in the same way as in the step 7).