Rear Drive Axle Disassembly

1. Remove axle assembly from vehicle, then axle shafts and carrier assembly.
2. Perform a pattern check before disassembling carrier to aid in determining what service should be performed.
3. Using a punch, mark bearing caps so they can be reinstalled in their original locations.
4. Remove nuts and bearing caps, then remove differential case and ring gear. Mark bearing races as to right or left so they can be reinstalled in their original locations.
5. Using suitable puller, remove differential side bearings. Record thickness of each shim pack and side bearing as it is removed and keep separated. These dimensions will be required during reassembly.
6. Remove ring gear bolts and separate ring gear from case. Use care when removing ring gear to avoid damaging differential case or ring gear. Do not force a chisel or other tools between joining surfaces.

Fig. 11 Removing pinion shaft:

7. On models less limited slip differential, proceed as follows:
a. Drive out pinion shaft lockpin using a drift. If necessary remove caulking in lockpin with a drill.
b. Remove pinion shaft using a drift, Fig. 4, then remove thrust block, pinion gears, side gears and thrust washers.

Fig. 6 Limited Slip Differential:

8. On models with limited slip differential, proceed as follows:
a. Mount differential carrier on to a suitable side gear holder, Fig. 5 then evenly and gradually remove four screws holding differential housing together.
b. Remove and lay out in order of disassembly for inspection, spring discs, friction plates, pressure rings, side gear and pinion shaft for both sides of differential carrier Fig. 6.
9. Remove pinion nut and companion flange. Do not discard nut as it will be required for bearing preload adjustment.

Fig. 12 Removing drive pinion:

10. Drive pinion from carrier by placing a soft metal rod against end of drive pinion and striking rod with hammer, Fig. 7. The outer (front) bearing will fall into carrier, while the inner (rear) bearing will remain in the carrier bores.
11. Using an arbor press and bearing removal tool No. J-22912, or equivalent, remove rear bearing from pinion.
12. Remove oil seal, then drive out outer races using a drift.