Disassembly

The valve body and solenoid wiring connector must be removed from the transaxle in order to recondition the transaxle differential. The transfer shaft cannot be removed with the valve body in place. Refer to Valve Body Disassembly And Assembly procedures for removal operations.
If any bearings in the differential require replacement, all the bearings on the differential carrier and transfer shaft must be replaced. The differential adjusters must also be replaced when differential bearings are replaced.

PROCEDURE

Fig. 364:

CAUTION: The chain sprockets have a slip fit onto their shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly removal or installation will be difficult. Overspreading of the chain sprocket will also make sprocket removal difficult.

Fig. 365:

Fig. 366:

CAUTION: To ensure proper gear ratio, verify that the correct chain and sprocket ratio is selected.

CAUTION: When reinstalling drive chains, the blue link must face outward.

Fig. 367:

Fig. 368:

Fig. 369:

Fig. 370:

CAUTION: Driveshaft retainer clips and seals located on the stub shafts must be replaced before reinstalling driveshafts.

Fig. 371:

Fig. 372:

Fig. 373:

Fig. 374:

If the carrier requires reconditioning, refer to Differential Carrier Recondition.

CAUTION: Failure to grind and open stakes on the transfer shaft nut will result in thread damage to transfer shaft during nut removal.

Fig. 375:

Fig. 376:

Fig. 377:

Fig. 378:

WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.

Fig. 379:

Fig. 380:

Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nut as shown in (Fig. 379) and (Fig. 380). Do not grind through the transfer shaft nut into the shaft. There are two stakes on the nut.

Fig. 381:

Fig. 382:

Using a small chisel, carefully open stakes on nut (Fig. 381)
Remove the transfer shaft nut.

CAUTION: Do not reuse old transfer shaft nut because the removed stake weakens the nut flange.

CAUTION: The transfer shaft cannot be removed from the case at this time.

Fig. 383:

Install special tool 6577 to remove rear transfer bearing cup (Fig. 383).

Fig. 384:

Fig. 385:

Remove transfer shaft preload shim (Fig. 384). If transfer shaft bearings are to be reused, the original shim must also be reused.

CAUTION: If the transfer shaft is removed from the transaxle case for any reason, both seals must be replaced.

Fig. 386:

Remove transfer shaft seals (Fig. 386) using special tool 6310 and foot 6310-9 (Tar 960). Do not reuse old seals. The seals will be pulled out the rear of the case.

Fig. 387:

Remove the front transfer shaft bearing cup using special tool 6495 and handle C-4171 (Fig. 387). Use a press with special tools to remove cup.

Fig. 388:

Support special tool P-334 on press table so that pinion head of transfer shaft can be pressed through table (Fig. 388).