Disassembly

1. To remove the actuator do the following.
a. Remove the bolt and actuator from the differential carrier.
b. Remove the O-ring.
2. Remove the indicator switch and gasket.
3. To remove the fork shaft do the following.





a. Using a hexagon wrench, remove the 2 straight screw plugs.
b. Remove the spring seat, compression spring and ball.





c. Using a pin punch and hammer, remove the slotted spring pin.
d. Remove the two bolts from the shaft retainer.





e. Using a plastic hammer, tap out the shaft retainer.
f. Remove the shift fork shaft.

NOTE: Pull out the shift fork shaft with a screwdriver turned round.





4. Remove the companion flange by performing the following.
a. Using a chisel and hammer, unstake the nut.
b. Using the 09330 - 00021 SST to hold the flange, remove the nut and plate washer.
c. Using the 09950 - 30010 (09951 - 03010, 09953 - 03010, 09954-03010, 09955-03030, 09956-03020) SSTs remove the companion flange.
5. Remove the oil seal and oil slinger by performing the following, using the 09308 - 10010 SST, remove the oil seal from the differential carrier, then remove the oil slinger.
6. Remove the rear bearing by using the 09556 - 22010 SST, and remove the rear bearing from the drive pinion.





7. To remove the differential case, do the following.
a. Place matchmarks on the bearing cap and differential carrier.
b. Remove the two adjusting nut locks.
c. Remove the four bolts and the two bearing caps.
d. Remove the differential case with the side bearing outer race, adjusting nuts and sleeve from the differential carrier then remove the shift fork.

8. To remove the drive pinion and bearing spacer do the following.
a. Remove the drive pinion with the front bearing.
b. Remove the bearing spacer.





9. Remove drive pinion front bearing by using the 09950 - 00020 SST and a press to remove the bearing from the drive pinion then remove the plate washer from the drive pinion.

NOTE: If the drive pinion or ring gear are damaged, replace them as a set.

10. Remove front and rear bearing outer races and oil storage ring by performing the following.





a. Using the 09308 - 00010 SST, remove the rear bearing outer race.





b. Using a brass bar and hammer, remove the oil storage ring and front bearing outer race.





11. To remove ring gear do the following.
a. Using a screwdriver and hammer, unstake the lock plate.
b. Place matchmarks on the ring gear and differential case.
c. Remove the ring gear set bolts and lock plates.
d. Using a plastic hammer, tap on the ring gear to separate it from the differential case.

12. Check the differential case runout by performing the following.
a. Install the differential case in the differential carrier and tighten the adjusting nut just to where there is no play in the bearing.





b. Using a dial indicator, measure the differential case runout. The maximum case runout should be 0.07 mm (0.0028 inch).
c. Remove the differential case.





13. Remove the side bearings from differential case by using the 09950 - 40010 (09951 - 04010, 09952 - 04020, 09953-04020, 09954-04010, 09955-04010, 09957-04010, 09958-04010), 09950-60010 (09951-00480) SSTs, and pulling the 2 side bearings from the differential case.

NOTE: Fix the claws of SST to the notches in the differential case.

14. Disassemble differential case by:
a. Placing matchmarks on the LH and RH cases.





b. Removing the 8 bolts uniformly, a little at a time.
c. Using a plastic hammer, separate the LH and RH cases.
d. Removing these parts from the RH differential case, the two side gears, two side gear thrust washers, spider gear, four pinion gears and the four pinion gear thrust washers.