Differential Assembly: Disassembly
- Remove differential assembly. See DIFFERENTIAL ASSEMBLY under REMOVAL & INSTALLATION. Remove differential cover bolts. Remove differential cover. Remove side gear shaft snap rings. Using a slide hammer, remove side gear shafts. Remove side gear shaft oil seals from differential. Install Differential Spreader (09571-50010 ) onto differential. See Fig 1.
- Install a dial indicator onto differential. See Fig 1. Tighten bolt on differential compressor until dial indicator shows differential has spread .0039" (.10 mm).CAUTION: DO NOT spread differential more than .008" (.2 mm).
- Remove snap ring on drive pinion side. Identify snap ring for reassembly. Using a hammer and Seal Replacer (09608-10010 ), tap on hammer 3-4 times to make a gap between side bearing outer race and snap ring. Remove snap ring on ring gear side. Identify snap ring for reassembly.
- Tighten bolt on Differential Spreader (09571-50010 ), pushing out outer race on ring gear side. Align outer race with indentation on inside of differential. While lifting ring gear side of gear assembly, push outer race toward inside of differential assembly. Remove outer race.
- Lifting ring gear side of differential carrier, remove differential carrier from differential. Using a hammer and chisel, loosen staked nut on pinion flange. Remove nut and pinion flange. Using a screwdriver, remove oil seal.
- Press drive pinion from differential. Remove oil slinger and front bearing. Press rear bearing from drive pinion. If drive pinion bearings are being replaced, remove outer races and adjusting washer from differential.
- Pull side bearing from ring gear. See Fig 2. Paint mating marks on ring gear and differential carrier. DO NOT use punch marks. Remove 10 ring gear bolts. Using a plastic-faced hammer, remove ring gear from differential carrier.
- Using a hammer and punch, remove pinion gear pin. Disassemble 2 differential pinions, 2 pinion thrust washers, 2 side gears and 2 side gear thrust washers. See Fig 3. Press dust deflector from companion flange. Press dust cover from side gear shaft.