Disassembly

Fig. 5 Typical differential case bearing removal:

Fig. 6 Differential pinion shaft removal. Models w/standard differential:

Fig. 7 Typical differential pinion removal. Models w/standard differential:

1. On models with rear axle speed sensor, remove pulse spider using a puller.
2. On all models, inspect differential case side bearings and remove, as needed, using a puller, Fig. 5. If differential case bearings are replaced, press bearing races from side bearing caps and housing (as equipped), using spacers. Take care not to distort caps and note installation position of bearing race shims, if equipped.
3. Remove and discard ring gear retaining bolts, then tap gear from case.
4. Remove differential pinion shaft as follows:
a. On all 300 series models, drive out pin securing pinion shaft, then remove shaft from case.
b. On all models except 300 series, drive pinion shaft out of retaining ring in direction ``A'' shown in Fig. 6, then remove shaft.
5. Mount differential case in vise with one side gear opening facing up, taking care not to damage machined surfaces.
6. Insert drive flange into side gear and rotate flange to position differential pinions at openings in case, Fig. 7, then remove pinions and side gears along with shims and diaphragm springs. Keep all components in order to ensure proper assembly. Components which are reused should be installed in original position.
7. Clean components with solvent, blow dry with compressed air, then coat components with axle lubricant to retard corrosion.
8. Inspect components and replace any damaged, distorted or excessively worn, noting the following:
a. Mate side bearings with races and check operation. Replace damaged, scored or improperly operating bearings.
b. Inspect pinions and side gears and replace as an assembly if teeth are broken, excessively worn or deeply scored.
c. Inspect case for damaged or distorted ring gear flange, and worn side gear bores and bearing surfaces.
d. Inspect ring gear for damage, distortion, and uneven or excessive wear. Ring gear and pinion must be replaced as an assembly.