Differentials & Drive Axles: Overhaul: Disassembly

NOTE: Information for 190 series is not available from manufacturer.

Clamp axle housing in a support so that axle shafts are fully supported. Remove rear cover and axle shafts. Remove bearing side cover bolts and push out of housing along with seal rings and shims. Mark all parts for correct left and right side reassembly reference.
Tilt case slightly and remove differential from housing. Mark relative position of ring gear to differential case. Remove ring gear attaching bolts and carefully remove ring gear from case. To disassemble case, remove roller bearings from case using a puller. Knock pinion shaft lock pin out of case and remove pinion shaft.

Fig 1: Removing Differential Assembly from Housing
On limited slip differentials, insert Assembly Mandrels (115 589 04 61 00 ) through case and side gears. Remove pinions and spherical washers. Remove right side gear and friction discs, keeping all parts in order for reassembly. Repeat procedure for left side. On standard differentials, lift out side gears, thrust washers and spherical washers.
To remove drive pinion, remove flange nut and flange. Drive pinion out of housing. Pry seal out of housing with screwdriver. Remove front bearing outer race from housing using press and mandrel. Remove rear bearing outer race from case using adapter. Remove roller bearing inner race from pinion using press plate.