Final Drive: Disassembly

NOTE: The differential is serviced as an assembly. The only parts that are serviceable within the differential are the differential bearing cups and cones. If any other part fails within the differential, you must replace the differential assembly along with the transfer shaft.

The transfer shaft should be removed for differential repair and bearing turning torque checking.

Remove the differential cover and bolts (Fig 1) (Fig 2).

Fig 1: Identifying Differential Cover Bolts
Courtesy of DAIMLERCHRYSLER CORP.

Fig 2: Removing Differential Cover
Courtesy of DAIMLERCHRYSLER CORP.
Remove the differential bearing retainer and bolts (Fig 3) (Fig 4).

Fig 3: Identifying Differential Retainer Bolts
Courtesy of DAIMLERCHRYSLER CORP.

Fig 4: Removing Bearing Retainer
Courtesy of DAIMLERCHRYSLER CORP.
Using a plastic hammer, remove extension housing/adapter plate on the right side of the transaxle.
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY TO PREVENT IT FROM ROLLING OUT OF HOUSING.
Remove differential assembly.
Set up dial indicator set C-3339 and tool C-4996 as shown in (Fig 5) (Fig 6) to measure side gear end play. Side gear end play must be within 0.001-0.013 in.

Fig 5: Checking Side Gear End Play (Extension Housing Side)
Courtesy of DAIMLERCHRYSLER CORP.

Fig 6: Checking Side Gear End Play (Ring Gear Side)
Courtesy of DAIMLERCHRYSLER CORP.
Use Miller Special Tool 5048, 5048-3 Collets, and L-4539-2 Button to remove the differential bearing cone on the extension housing side.
Use Miller Special Tool 5048, 5048-4 Collets, and L-4539-2 Button to remove the differential bearing cone on the bearing retainer side (Fig 7) (Fig 8) (Fig 9).

Fig 7: Positioning Button and Collets Onto Differential and Bearing (Ring Gear Side)
Courtesy of DAIMLERCHRYSLER CORP.

Fig 8: Positioning Tool 5048 Over Button and Collets at Differential Bearing (Ring Gear Side)
Courtesy of DAIMLERCHRYSLER CORP.

Fig 9: Removing Differential Bearing Cone (Ring Gear Side)
Courtesy of DAIMLERCHRYSLER CORP.
Using Miller Special Tool L-4518, remove the differential bearing race from the extension housing/ adapter plate.

Using Miller Special Tool 6062A, remove the differential bearing race from the bearing retainer (Fig 10) (Fig 11).

Fig 10: Positioning Bearing Cup Remover Tool in Retainer

Courtesy of DAIMLERCHRYSLER CORP.

Fig 11: Removing Bearing Cup

Courtesy of DAIMLERCHRYSLER CORP.

DIFFERENTIAL SERVICE TOOLS

COMPONENT	REMOVER	INSTALLER
Diff. Bear. On Retainer Side	5048, 5048-4 Collets, L-4539-2 Button	5052, C-4171
Diff. Bear. On Ext. Hous. Side	5048, 5048-3 Collets, L-4539-2 Button	L-4410, C-4171
Diff. Race. On Retainer Side	6062-A	6061, C-4171
Diff. Race. On Ext. Hous. Side	L-4518	L-4520, C-4171
Extension Housing Seal	7794-A, C-637 Slide Hammer	L-4520, C-4171
Bearing Retainer Seal	794-A, C-637 Slide Hammer	L-4520, C-4171