Disassembly

DISASSEMBLY








1. Remove pinion housing assembly (4).





2. Remove pinion flange nut: Install Tool 6958 (1) as shown.





3. Using suitable socket (1) remove pinion flange nut.





4. Using puller 1026 (1), remove pinion flange.





5. Using suitable screwdriver, remove pinion seal (1).





6. Remove pinion housing assembly bolts (1)





7. Remove pinion depth shim (1).





8. Remove pinion housing O-ring seal (1).





9. Measure pinion housing assembly rotating torque. Rotating torque should be 130 - 250 N-cm (12 - 22 inch lbs.). If rotating torque is outside of this range, bearing replacement is required. Refer to Pinion Housing Disassembly.





10. Measure differential rotating torque with Tool C-4995-A. Rotating torque should be within 190 - 260 N-cm (17 - 23 inch lbs.). Measurements recorded out of this range require differential side bearing replacement and/or side bearing preload adjustment.





11. Remove axle housing cover (5). Remove differential assembly (3) and inboard axle seal (2).





12. Remove axle housing cover O-ring (1).

PINION HOUSING DISASSEMBLY





1. Press pinion gear/shaft (2) out of housing. Use suitable adapter (1) to protect end of shaft.





2. Remove pinion bearing spacer (1)





Using splitter 1130 or equivalent (2), press off pinion head bearing (1).





3. Using a suitable punch, remove pinion tail bearing cup (1).





4. Using suitable punch, remove pinion head bearing cup (1).

DIFFERENTIAL DISASSEMBLY

NOTE: The differential ring gear is welded to the differential case and is not serviceable separately.





1. Rotate differential side gears about case and remove side gears (2) and thrust washers (1).





2. Using suitable punch, drive pinion shaft roll pin (1) into case until it bottoms.





3. Remove pinion shaft (1), pinion gears (3) and thrust washers (2). Drive out and discard pinion shaft roll pin.





4. Using Tool 9676 (1) and Tool 1130 (3), press differential side bearing (2) off of ring gear side and discard.





5. Using Tool 9676 (1) and Tool 1130 (3), press differential side bearing (2) off of opposite side and discard.

AXLE HOUSING





1. Remove differential side bearing cup from axle housing cover. Install Tool 6514 (1) as shown.





2. Remove differential side bearing cup with Tool 6514 (1).

NOTE: Side bearing preload shims affect adjust differential bearing preload and ring gear backlash and must not be mixed up. Measure and tag side bearing preload shims upon removal.





3. Remove side bearing preload shim (1).





4. Measure preload shim (1) to identify for replacement.





5. Using Tool 9664 (1) and Slide Hammer C-637 (2), remove and discard inboard differential side bearing cup.





6. Remove side bearing preload shim from housing (1) -




7. Measure preload shim (1) to identify for replacement.