Disassembly

DIFFERENTIAL ASSEMBLY


Disassembly

1. Drain gear oil, if necessary.
2. Remove the side oil seal, using a suitable tool.

CAUTION:
Never damage gear carrier and rear cover.
3. Remove rear cover mounting bolts.





4. Set drift (A) and base tube (B) to the right and left side bearing adjusting washers individually. Press differential case assembly with side bearing to remove gear carrier assembly and rear cover assembly.

A : Drift [SST: KV38109220 ( - )]
B : Base tube [SST: KV38109210 ( - )]


CAUTION:
The pressure shall be as low as possible to remove gear carrier assembly and rear cover assembly. The maximum pressure shall be 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE:
Differential case assembly, side bearings, and adjusting washers are compressed and integrated in gear carrier and rear cover.
5. Remove side bearing adjusting washers and side bearing outer races.

CAUTION:
Mark the side bearing adjusting washers so that the original mounting positions (right/left) can be identified later.





6. Remove side bearing inner races, using puller (A) and the adaptor (B).
To prevent damage to bearing, engage puller jaws in groove (arrow).

A : Puller [SST: ST33051001 (J-22888-20)]
B : Adaptor [SST: KV40104840 ( - )]


CAUTION:
- To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
- It is not necessary to remove side bearing inner race except when it is replaced.





7. For proper reinstallation, paint matching marks on one differential case assembly.

CAUTION:
For matching marks, use paint. Never damage differential case and drive gear.
8. Remove drive gear mounting bolts.
9. Tap drive gear off differential case assembly with a soft hammer.

CAUTION:
Tap evenly all around to keep drive gear from bending.





10. Remove lock pin of pinion mate shaft with a punch from drive gear side.





11. Remove pinion mate shaft.





12. Turn pinion mate gear, then remove pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from differential case.
13. Perform inspection after disassembly. Inspection.