Disassembly

CAUTION: Use protective plates in the vise to prevent damage to the differential.

NOTE: Prior to disassembly, measure the backlash of the side gear and pinion gear. Check for damaged or worn gears and a cracked or damaged gear case. If not as specified, replace the differential assembly.





1. Use Dial Indicator With Bracketry TOOL-4201-C to measure the backlash of the differential side gears and pinion gears.
(1) Install the left and right front wheel driveshaft and joints into the differential assembly. Support the front wheel driveshaft and joints on V-blocks.
(2) Using Dial Indicator With Bracketry TOOL-4201-C and with Magnetic Base/Flex Arm D78P-4201C, measure the backlash of the differential side gears and pinion gears. The standard backlash should be 0.025-0.1 mm (0.001-0.004 inch); the maximum backlash is 0.5 mm (0.020 inch). If the backlash is more than allowable, replace the differential as an assembly.





2. Remove the differential pinion shaft lock pin. Use a 2.0 mm (5/64 inch) pin punch and hammer.





3. Remove the differential pinion shaft.





4. Remove the differential pinion gears, differential side gears, differential pinion thrust washers, and the differential side gear thrust washers.





5. Use (A) Bearing Puller Attachment D84L-1123-A, (B) Push-Puller Legs D80L-927-A, and (C) step plate D80L-630-3 to remove the (D) differential bearing (speedometer drive gear end).





6. Remove the speedometer drive gear.





7. Use (A) Step Plate D80L-630-3 and (B) Puller-Differential Side Bearing T77F-4220-B1 to remove the (C) differential bearing (ring gear end).