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.
Use Dial Indicator/Magnetic Base to measure the backlash of the side gears and pinions. If backlash is not within specification, replace the differential as an assembly.
Install the LH and RH halfshafts.
Support the halfshafts on V-blocks.
Measure the backlash of the side gears and pinions.
Remove the differential pinion shaft lock pin.
Use a 2.0 mm (5/64 inch) pin punch and hammer.
Remove the differential pinion shaft.
Remove the differential pinion gears, differential side gears, differential pinion thrust washers, and the differential side gear thrust washers.
Use (A) Bearing Puller Attachment, (B) Push-Puller Legs, and (C) Step Plate to remove the (D) differential bearing (speedometer drive gear end).
Remove the speedometer drive gear.
Use (A) Step Plate and (B) Puller-Differential Side Bearing to remove the (C) differential bearing (ring gear end).
Assembly
Clean the components with a suitable solvent and use compressed air to dry all parts. Perform the following before assembly:
Check for damaged or worn gears and washers.
Inspect the speedometer drive gear for damage or wear.
Install the speedometer drive gear.
Use (A) Driver Handle or a press, along with (B) Bearing Cone Replacer to install a new (C) differential bearing (speedometer drive gear end).
Use (A) Driver Handle or a press, along with (B) Bearing Cone Replacer to install a new (C) differential bearing (ring gear end).
Install the differential side gear thrust washers, differential pinion thrust washers, differential pinion gears, and the differential side gears.
Rotate the gears to align the differential gears with the pinion shaft hole.
Install the differential pinion shaft.
Install the differential pinion shaft lock pin. Stake the differential pinion shaft lock pin to prevent it from coming out of the differential case.
