Differential and Bevel Gear (Front and Rear) - Disassemble
Disassembly Procedure
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| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 1U-7502 | Repair Stand | 1 |
| B | 3H-0465 | Push-Puller Plate | 2 |
| 5F-7345 | Screw | 2 | |
| 8B-7551 | Bearing Puller | 1 | |
| 1P-5546 | Crossblock | 1 | |
| 7F-9540 | Hydraulic Cylinder | 1 | |
| 1P-0520 | Driver Group | 1 | |
| 9U-6600 | Pump | 1 | |
| C | 138-7573 | Link Bracket | 2 |
| D | 1P-0520 | Driver Group | 1 |
| E | 150-0361 | Support Bracket Assembly | 1 |
| F | 8T-0832 | Cape Chisel | 1 |
| G | 8B-7551 | Bearing Puller | 1 |
| M | 6V-7920 | Spanner Wrench | 1 |
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| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Apply location marks on all housings and case assemblies for assembly purposes.
- Install differential assembly (2) to Tooling (A) .
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| Illustration 1 | g00510943 |
- Remove Tooling (C) . Remove the lifting strap. Remove the hoist.
- Remove external fitting (1) from differential assembly (2) .
- Rotate the differential assembly by 90 degrees.
- Remove four bolts and washers (3) that hold housing (4) for the differential lock in place.
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| Illustration 2 | g00511027 |
- Remove housing (4) for the differential lock from the differential assembly.
- Remove bearing (5) from the differential assembly.
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| Illustration 3 | g00511032 |
- Remove bearing race (6) from the differential assembly.
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| Illustration 4 | g00511036 |
- Remove discs and plates (7) from the differential assembly. Keep discs and plates (7) in order.
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| Illustration 5 | g00511092 |
- Remove gear (8) from the differential assembly. The gear may be removed by hand.
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| Illustration 6 | g00511109 |
- Remove hub (9) from the differential assembly.
Note: Three coil springs are loosely attached to hub (9) . The coil springs do not need to be removed. The coil springs should be inspected for damage. Replace all three of the coil springs if any of the springs are damaged.
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| Illustration 7 | g00511131 |
- Remove bearing (10) from the differential assembly.
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| Illustration 8 | g00511378 |
- Remove four Torx screws (12) . Remove lower bearing race (11) from the differential assembly.
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| Illustration 9 | g00511386 |
- Rotate the differential housing by 90 degrees. Remove four bolts and washers (13) that hold bearing caps (14) in place. Remove bearing caps (14) from the differential housing.
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| Illustration 10 | g00511394 |
- Attach a lifting strap around differential carrier (15) . Remove differential carrier (15) . Do not allow outer races (16) of the bearings to fall from the carrier. Remove outer races and adjusting nuts (16) .
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| Illustration 11 | g00511445 |
- Place differential carrier (15) on a clean work surface. Install Tooling (B) in order to remove bearing (17) . Rotate the differential carrier by 180 degrees. Use the same tooling in order to remove the other bearing.
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| Illustration 12 | g00511807 |
- Remove 28 bolts (18) that secure ring gear (19) to differential carrier (15) .
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| Illustration 13 | g00514465 |
- Place the differential carrier in a press. Use Tooling (D) and the hydraulic press in order to remove ring gear (19) from the differential carrier. Cushion the differential carrier in order to prevent damage to the differential carrier when the differential carrier drops.
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| Illustration 14 | g00514466 |
- Remove 12 bolts (21) that secure housing (20) of the differential case to hub (22) of the differential case. Rotate the differential case by 180 degrees. Remove hub (22) from housing (20) .
Note: Find the location marks from manufacturing that are on the differential case. Place location marks on the housing if location marks are not found.
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| Illustration 15 | g00514935 |
- Remove thrust washer (23) from bevel gear (24) . Remove bevel gear (24) from housing (20) .
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| Illustration 16 | g00514937 |
- Remove gears (25) , gear shafts (26) , and thrust washers (27) from housing (20) .
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| Illustration 17 | g00514939 |
- Remove thrust washers (27) from shafts (26) . Remove gears (25) from the shafts (26) .
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| Illustration 18 | g00514940 |
- Remove bevel gear (28) from housing (20) .
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| Illustration 19 | g00514942 |
- Remove thrust washer (29) from bevel gear (28) .
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| Illustration 20 | g00514943 |
- Rotate differential assembly (2) by 180 degrees. Remove bolt (31) . Remove yoke (30) from the differential. Yoke (30) may be removed by pulling up on the yoke with your hands.
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| Illustration 21 | g00514945 |
- Rotate differential assembly (2) by 180 degrees. Install Tooling (E) . Tooling (E) is held in place by bearing caps (14) . Install bearing caps (14) . Tooling (E) prevents the pinion from falling during removal of the pinion.
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| Illustration 22 | g00514952 |
- Tooling (E) has adjusting screw (32) . Turn screw (32) until the screw contacts pinion (33) .
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| Illustration 23 | g00514954 |
- Rotate differential assembly (2) by 180 degrees. Remove six bolts (34) from the seal retainer (35) . Remove seal retainer (35) . Inspect the gasket for the seal retainer. Replace the gasket if the gasket is damaged.
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| Illustration 24 | g00514946 |
- Remove seal (36) from seal retainer (35) .
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| Illustration 25 | g00514948 |
- Use Tooling (F) in order to remove the staked portion of nut (37) .
Note: If nut (37) is equipped with set screws, loosen the set screws. Tooling (F) is not needed.
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| Illustration 26 | g00514964 |
- Place a wrench on nut (37) . Install yoke (30) on the splined portion of pinion shaft (38) . Hold yoke (30) with a wrench. Remove nut (37) with the other wrench.
Note: If nut (37) is equipped with set screws, use Tooling (M) in order to remove the nut.
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| Illustration 27 | g00514965 |
- Remove ten bolts (43) from bearing cage (41) .
- Remove washer (39) from pinion shaft (38) .
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| Illustration 28 | g00514966 |
- Remove bearing (40) from pinion shaft (38) .
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| Illustration 29 | g00517160 |
- Bearing cage (41) has three threaded holes (40) for inserting forcing screws. Use three of the bolts that were removed from bearing cage (41) as forcing screws. Install the forcing screws in threaded holes (40) . Remove bearing cage (41) from the differential carrier. Inspect the seal for the bearing cage. Replace the seal if the seal is damaged.
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| Illustration 30 | g00517166 |
- Remove the inner bearing race from bearing cage (41) . The inner bearing race is a press fit.
- Rotate the differential carrier until you can remove four bolts and washers (13) that hold the bearing caps in place. Remove Tooling (E) . Remove pinion (38) .
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| Illustration 31 | g00514962 |
- Remove outer race (45) for the inner pinion bearing with a proper driver. Remove the shim pack that is located under outer race (45) .
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| Illustration 32 | g00514960 |
- Install Tooling (G) . Place pinion shaft (38) in a press in order to remove bearing (46) .
Note: Do not allow the pinion shaft to fall.
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| Illustration 33 | g00514956 |
- Remove bolts, washers, and spacers (53) which hold piston (52) in housing (4) . Remove piston (52) .
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| Illustration 34 | g00520964 |
- Remove O-rings (50) and (51) from the piston (52) . The O-rings should be replaced with new O-rings.
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| Illustration 35 | g00520922 |
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