Disassembly

Fig. 16 Disassembled View Of AWD Differential.:

1. Place differential carrier into a suitable working fixture.
2. Remove side gear shafts, Fig. 16.
3. Remove side gear shaft oil seals.
4. Using suitable tools, remove companion flange.
5. Remove front oil seal and oil slinger.
6. Remove front bearing and bearing spacer.
7. Remove differential case. Proceed as follows:
a. Place alignment marks on the bearing cap and differential carrier.
b. Remove the two bearing caps.
c. Using tool 09504-22011 or equivalent, remove the two side bearing preload adjusting plate.
d. Measure adjusting plate washer and note thickness.
e. Remove differential case and bearing outer race from carrier.
f. Tag bearing outer races for identification.
8. Remove drive pinion from differential carrier.
9. Remove drive pinion rear bearing, front and rear bearing outer races.
10. Remove ring gear and side bearings.
11. Remove straight pin, pinion shaft, two pinion gears, side gears and thrust washers from differential case.