Disassembly

Fig. 31 Exploded View Of Differential Assembly. Supra:

1. Drain lubricant, then remove differential carrier cover attaching bolts and the cover, Fig. 31.
2. Using suitable dial indicator, measure ring gear runout. If runout exceeds .0028 inch, replace ring gear.
3. With dial indicator positioned 90° to ring gear teeth surface, hold drive pinion flange while measuring ring gear backlash. Backlash should be .0051-.0071 inch. If backlash is not within specifications, it must be adjusted.

Fig. 6 Preload (rotating Torque) Measurement:

4. Using suitable inch lbs. torque wrench mounted on pinion nut, Fig. 6, measure and record starting preload of the ring and pinion backlash. Preload should be 4.3-6.9 inch lbs.
5. With wrench positioned as above, measure and record the total starting preload of ring and pinion assembly. Total preload should be 3.5-5.2 inch lbs. plus drive pinion preload measured in step 4, above.
6. Using suitable hammer and chisel, unstake pinion nut.
7. While holding companion flange from turning with tool 09330-00021, remove pinion nut.
8. Remove companion flange with suitable puller.
9. Remove pinion oil seal and oil slinger from differential carrier.
10. Remove pinion rear bearing using suitable puller, then the spacer.
11. Remove side gear shaft from differential with puller 09520-24010.
12. Remove side gear shaft oil seal with puller 09308-00010.
13. Place reference marks between bearing caps and differential carrier, then remove bearing cap bolts and caps.
14. Remove two side bearing preload adjusting shims.
15. Lift differential case with bearing outer races from differential carrier.
16. Tag outer races to show which side they were removed from.
17. Remove drive pinion from differential carrier.
18. If necessary to replace drive pinion rear bearing, remove rear bearing from drive pinion, using press and tool No. 09950-00020. If drive pinion or ring gear are damaged, they must be replaced as a set.
19. If necessary to replace drive pinion front and rear bearing outer race, drive out outer bearing race using a hammer and suitable drift.
20. If necessary to replace differential side bearings, remove with puller 09950-20017.
21. If ring gear replacement is necessary, proceed as follows:
a. Make reference marks between ring gear and differential case.
b. Bend back attaching bolt lock plates, then remove ring gear attaching bolts and lock plates.
c. Tap on ring gear with plastic mallet to separate it from differential case.