Disassembly

40TE AUTOMATIC TRANSAXLE

FINAL DRIVE

DISASSEMBLY

Fig.162 Differential Cover Bolts:

NOTE: The transfer shaft should be removed for differential repair and bearing turning torque checking.

(1) Remove the differential cover and bolts (1) (Fig. 162).

Fig.163 Differential Retainer Bolts:

(2) Remove the differential bearing retainer bolts (1) (Fig. 163).

Fig.164 Remove Bearing Retainer:

(3) Remove the differential bearing retainer (1) (Fig. 164) using Holder L-4435 (2).
(4) Using a plastic hammer, remove extension housing/adapter plate on the right side of the transaxle.

WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY TO PREVENT IT FROM ROLLING OUT OF HOUSING.

Fig.165 Checking Side Gear End Play (Extension Housing Side):

(5) Remove differential assembly.

(6) Set up Dial Indicator Set C-3339 (2) and Adapter C-4996 (1) (Fig. 165) to measure side gear end play (Extension Housing Side). Side gear end play must be within 0.001 - 0.013 inch.

Fig.166 Checking Side Gear End Play (Ring Gear Side):

(7) Set up Dial Indicator Set C-3339 (2) and Adapter C-4996 (1) (Fig. 166) to measure side gear end play (Ring Gear Side). Side gear end play must be within 0.001 - 0.013 inch.

Fig. 167 Button L-4539-2 And Collets 5048-4:

(8) Remove differential side bearing cone (3) (Fig. 167) from ring gear side of differential. Install button L-4539-2 (2), and Collets 5048-4 (1).

Fig.168 Side Bearing Removal Using Tool 5048 (Ring Gear Side):

(9) Install Puller Set 5048 (1) (Fig. 168), collets 5048-4 (2) and sleeve. Remove and discard bearing cone.

Fig.169 Install Button L-4539-2:

(10) Remove differential side bearing cone from outboard end (opposite ring gear) of differential. Install Button L-4539-2 (1) (Fig. 169).

Fig.170 Side Bearing Removal Using Tool 5048:

(11) Install Puller Set 5048 (1) (Fig. 170), (2) collets 5048-3 and sleeve. Remove and discard bearing cone.

Fig.171 Remove/Install Retainer/Ring Gear Bolt:

(12) Remove pinion shaft retainer plate bolts (1) (Fig. 171).

Fig.172 Pinion Shaft Retainer:

(13) Remove pinion shaft retainer (1) (Fig. 172).

Fig.173 Pinion Shaft Removal/Installation:

(14) Remove pinion shaft (1) (Fig. 173) from differential case.

Fig.174 Pinion Gear And Washer:

(15) Rotate pinion gears (2) (Fig. 174) about case and remove (w/washer) (1).

Fig.175 Side Gear Removal/Installation:

(16) Remove differential side gears (1) (Fig. 175).

Fig.176 Side Gear Washer:

(17) Remove side gear thrust washers (1) (Fig. 176).

Fig.177 Ring Gear Bolt Removal/Installation:

(18) Remove remaining differential ring gear-to-case bolts (1) (Fig. 177).

Fig.178 Ring Gear Removal:

(19) Using a soft-faced hammer (1) (Fig. 178), remove ring gear (2) from case.

Fig.179 Position Bearing Cup Remover Tool In Retainer:

(20) Using Jaw Set 6062A (Fig. 179), remove the differential bearing race from the extension housing/adapter plate.

Fig. 180 Remove Bearing Cup:

(21) Using Jaw Set 6062A (Fig. 180), remove the differential bearing race from the bearing retainer.

40TE AUTOMATIC TRANSAXLE DIFFERENTIAL SERVICE TOOLS:

DIFFERENTIAL SERVICE TOOLS