Differentials & Drive Axles: Overhaul: Disassembly
- Mount carrier in a repair stand. Punch identification marks on side bearing supports of carrier, differential bearing caps and side bearing adjusters as reference marks for reassembly. Remove adjuster lock plates, loosen bearing cap attaching nuts or bolts, and slightly back off adjusters to relieve preload.
- Remove bearing caps and adjusters, then withdraw differential assembly from carrier, making sure side bearing races remain with their respective bearings.
- Hold companion flange with Coupling Flange Holder (49 0259 710A ) and remove drive pinion nut. Remove companion flange using a common gear puller of the appropriate size. Remove drive pinion, spacer, rear bearing and collapsible spacer assembly from carrier.
- Remove oil seal and front bearing. If necessary, remove bearing outer races using a drift in slots provided on inner lip. Using Puller (49 0839 425C ), remove side bearings from gear case. Straighten lock tabs, remove ring gear attaching bolts and separate ring gear from gear case.
- On limited slip differentials, gradually loosen attaching screws until distance between left and right half of differential case is about 0.12" (3 mm). Then carefully separate differential halves. Remove the following parts: Thrust washer, conical spring, friction plates, friction discs, pressure ring, side gear, pinion gear and spider. Keep parts in order for reassembly. See Figure .
- On conventional differentials, remove ring gear. Drive out differential pinion shaft lock pin with a punch and remove pinion shaft. Rotate pinion gears 90° and remove gears, thrust washer, thrust block (if equipped) and differential side gears.
- Inspect all parts for chipped or worn teeth, damaged bearing journals, cracks, flaking or any damage. Replace defective parts as necessary.