Differential - Disassembly

42LE - Automatic Transaxle
DIFFERENTIAL - DISASSEMBLY







1. Remove ring gear-to-carrier bolts (Fig. 168).







2. Using a plastic or soft-tipped hammer, tap ring gear off of carrier (Fig. 169).







3. Using suitable pry tools, pry differential carrier apart (Fig. 170).







4. Remove stub shaft C-clip (Fig. 171).







5. Using a suitable punch, remove pinion shaft roll pin (Fig. 172).







6. Remove differential pinion shaft. Remove pinion and side gears (Fig. 173).







7. Using tool C-293-PA, adapters C-293-48, and adapter C4996, remove differential carrier bearings (Fig. 174).







14. Remove inner adjuster (Fig. 175).







15. Remove differential vent baffle (Fig. 176).

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

WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.










16. Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nut as shown in (Fig. 177) and (Fig. 178). Do not grind through the transfer shaft nut into the shaft. There are two stakes on the nut.







17. Using a small chisel, carefully open stakes on nut (Fig. 179)







18. Remove the transfer shaft nut (Fig. 180).

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.







19. Install special tool 6577 to remove rear transfer bearing cup (Fig. 181).







20. Remove transfer shaft preload shim (Fig. 182). If transfer shaft bearings are to be reused, the original shim must also be reused.







21. Remove transfer shaft assembly from case (Fig. 183).

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







22. Remove transfer shaft seals using special tool 6310 and foot 6310-9 (Fig. 184). Do not reuse old seals. The seals will be pulled out the rear of the case.







23. Remove the front transfer shaft bearing cup using special tool 6495 and handle C-4171 (Fig. 185). Use a press with special tools to remove cup.







24. Support special tool P-334 on press table so that pinion head of transfer shaft can be pressed through table (Fig. 186).