Disassembly/Assembly

NOTE: Heat tapered roller bearing inner races to 100°C (212°F) before pressing them on.





1. Differential cover
- Removing and installing, refer to Removal/Installation
2. Drive gear
- For Speedometer Vehicle Speed Sensor (VSS)
- Removing and installing, refer to Removal/Installation
3. Shim S1
- Determining thickness, refer to Ring, Pinion and Input Gear. Adjustments
4. Tapered roller bearing outer race
- Drive out using drift
- Pressing in, refer to Fig. 1, below
5. Tapered roller bearing inner race
- Removing, refer to Fig. 2, below
- Pressing on, refer to Fig. 3, below
6. Bolt
- Tighten to: 80 Nm (59 ft lb) + 1/6-turn (60°)
7. Differential housing
- If replaced, ring gear must be adjusted, refer to Ring, Pinion and Input Gear. Adjustments
8. Ring gear
- Number of teeth, refer to; Description and Operation / Transmission Applications, Ratios, Equipment.
- Matched to pinion
- If damaged, replace pinion and ring gear as a set
- Pinion and ring gear must be adjusted when gear set is replaced, refer to Ring, Pinion and Input Gear. Adjustments
- Drive out of differential housing using drift
- Installing: heat to 10°C (212°F)
- Use centering pins, refer to Fig. 4, below
9. Tapered roller bearing inner race
- Removing, refer to Fig. 2, below
- Pressing on, refer to Fig. 3, below
10. Tapered roller bearing outer race
- Drive out using drift
- Driving in, refer to Fig. 5, below
11. Shim S2
- Determining thickness, refer to Ring, Pinion and Input Gear. Adjustments
12. Transmission housing
13. Thrust washer assembly
- Place in differential housing before installing bevel gears
14. Large bevel gears
- Installing, refer to Fig. 6, below
15. Small bevel gears
- Installing, refer to Fig. 6, below
16. Threaded washer
- Insert lugs into large bevel gear during assembly
- Install before shaft (item 17 in illustration)
17. Shaft for small bevel gears
- Drive out using drift
- Check for wear and replace if necessary
- Do not damage thrust washer assembly when driving in
18. Circlip

CAUTION:
^ Do not remove circlip (18 in illustration) until after the drive flange has been removed.
^ The drive flange is pre-loaded with spring pressure because of the compression spring.

19. Drive flange output shaft





Fig. 1 Pressing in tapered roller bearing outer race





Fig. 2 Removing tapered roller bearing inner race
- Place thrust piece (special tool 40-105) against differential housing.





Fig. 3 Pressing off tapered roller bearing inner race





Fig. 4 Installing ring gear
(A in illustration) Centering pins (quantity 2, local manufacture)
- Heat ring gear to approx. 100°C (212°F).





Fig. 5 Driving in tapered roller bearing outer race
- To prevent misalignment, first lightly drive in outer race using brass pin.





Fig. 6 Installing differential bevel gears
- Lubricate thrust washer assembly with gear oil and install.
- Install large bevel gears (with threaded washer at ring gear end).
- Install drive flange and output shaft to align gears.
- Insert small bevel gears (offset 180�) and swing in by turning drive flange.
- Drive in shaft for small bevel gears.