Disassembly and Assembly: Disassembly

Differential side shaft

1. Drain the differential gear oil if necessary.
2. Remove the carrier cover bolts and separate the carrier cover from the gear carrier using Tool.

   Tool number: KV10111100 (J-37228) 

   CAUTION:

   • Do not damage the mating surface.
   • Do not insert flat-bladed screwdriver, this will damage the mating surface.
   Fig 1: Separating Carrier Cover From Gear Carrier Using Tool

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3. Remove side oil seal, using suitable tool.
   CAUTION: Do not damage gear carrier.
   Fig 2: Removing Side Oil Seal

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4. Remove snap ring (hole side) using suitable tool.
   Fig 3: Removing Snap Ring (Hole Side) Using Tool

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5. Remove differential side shaft assembly out of gear carrier using suitable tool.
   NOTE: Tap on differential side shaft assembly from side gear side.
6. Remove snap ring (differential side shaft side).
   Fig 4: Removing Side Shaft Assembly From Gear Carrier

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7. Press differential side shaft out of differential side shaft bearing.
   CAUTION: Do not drop differential side shaft.
   Fig 5: Pressing Differential Side Shaft Out Of Side Shaft Bearing

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Differential Assembly

1. Remove differential side shaft assembly. Refer to "REMOVAL AND INSTALLATION ".
2. Remove side seal from gear carrier using suitable tool.
3. For proper reinstallation, paint matching marks on one side of the side bearing cap and gear carrier.
   CAUTION:

   • For matching marks, use paint. Do not damage side bearing cap or gear carrier.
   • Side bearing caps are line-board during manufacture. The matching marks are used to reinstall them in their original positions.
   Fig 6: Identifying Matching Mark On Bearing Cap And Gear Carrier

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4. Remove the side bearing caps.
   Fig 7: Removing Side Bearing Caps

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5. Lift the differential case assembly out of the gear carrier.
   CAUTION:

   • Keep side bearing outer races together with side bearing inner races. Do not mix them up.
   • Keep side bearing adjusting washers together with side bearings.
   Fig 8: Lifting Differential Case Assembly Out Of Gear Carrier

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6. Remove housing spacer.
7. Remove side bearing inner race using Tools as shown.

   Tool number (A): ST33051001 (J-22888-20) 

   (B): ST33061000 (J-8107-2) 

   CAUTION:

   • Do not remove side bearing inner race unless it is being replaced.
   • Place copper plates between the vise and the side bearing inner race and drive gear to prevent damage.
     Fig 9: Removing Side Bearing Inner Race Using Tools

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   • Keep side bearing outer races together with side bearing inner races. Do not mix them up.
   Fig 10: Identifying Left And Right Side Parts Label

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8. For proper reinstallation, paint matching marks on the differential case and drive gear.
   CAUTION: Use paint for matching marks. Do not damage differential case or drive gear.
9. Remove the drive gear bolts.
10. Tap the drive gear off the differential case using suitable tool.
    CAUTION: Tap evenly all around to keep drive gear from bending.
    Fig 11: Identifying Matching Mark On Differential Case Assembly

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11. Remove the lock pin of the pinion mate shaft from the drive gear side using suitable tool.
    Fig 12: Removing Pinion Mate Shaft Lock Pin Using Tool

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12. Remove the pinion mate shaft.
    Fig 13: Removing Pinion Mate Shaft

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13. Turn the pinion mate gear, then remove the pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from the differential case.
    Fig 14: Turning Pinion Mate Gear

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Drive Pinion Assembly

1. Remove the differential assembly.
2. Remove the drive pinion lock nut using suitable tool.
3. Put matching marks on the companion flange and drive pinion using paint.
   CAUTION: Use paint to make the matching marks. Do not damage the companion flange or drive pinion.
   Fig 15: Removing Drive Pinion Lock Nut Using Tool

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4. Remove the companion flange using suitable tool.
   Fig 16: Removing Companion Flange Using Tool

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5. Press the drive pinion assembly (with rear inner bearing race and collapsible spacer) out of the gear carrier.
   CAUTION: Do not drop drive pinion assembly.
   Fig 17: Pressing Drive Pinion Assembly

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6. Remove the drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool.

   Tool number: ST30031000 (J-22912-01) 

   Fig 18: Removing Drive Pinion Rear Bearing Inner Race Using Tool

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7. Remove the front oil seal using suitable tool.
   CAUTION: Do not damage gear carrier.
   Fig 19: Removing Front Oil Seal Using Tool

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8. Remove the drive pinion front bearing inner race.
9. Remove the drive pinion front and rear bearing outer races by tapping them uniformly using suitable tool.
   CAUTION: Do not damage gear carrier.
   Fig 20: Taping Pinion Front/Rear Bearing Outer Races Using Tool

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