Disassembly

Disassembly





1) Remove front drive shaft (1) from differential housing (2) by using plastic hammer.





2) Remove 8 bolts (1) for fastening differential carrier (2) of which are reamer bolts (2)) and then take differential assembly out of housing.





3) Set special tool on vise (1) securely.
4) Using 4 bolt and nut sets, set differential assembly onto differential carrier holder and put identification marks ("A") on differential side bearing caps (6). Remove differential inner hose and actuator bracket bolt.
5) Take off differential side bearing lock plates (4) and differential side bearing caps (6) removing their bolts and then take out bearing adjusters (5), side bearing outer races and drive bevel gear with differential case (3).





6) Turn differential assembly together with special tool by 90 degrees and grip it with vise again.





7) Remove air inlet union (2) from differential carrier (1).





8) Hold universal joint flange with special tool and then remove flange nut by using power wrench.
9) Make mating marks (1) on drive bevel pinion and companion flange.

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





10) Remove companion flange from pinion. Use special tool if it is hard to remove.





11) Remove bevel pinion with front bearing, 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.





12) Using special tools, pull out differential side bearings.





13) With aluminum plates (3) placed on vise first, grip differential case with it and remove bevel gear (2) by removing its 10 bolts (1).

CAUTION: Use care not to hold axle lock clutch part with vise. Be sure to hold differential left case.





14) Separate differential case assembly by removing 2 screws (2) and take out free axle hub, side gears and shims from differential left case (1).





15) Remove bevel pinion front bearing (2) by using bearing puller (3) and press.





16) Drive out bevel pinion bearing outer races in differential carrier by hammering metal stick applied to them.