Differentials & Drive Axles: Overhaul: Disassembly

Mount carrier in a repair stand. Punch identification marks on side bearing supports of carrier, differential bearing caps and side bearing adjusters. Remove adjuster lock plates, loosen bearing cap attaching nuts or bolts, and slightly back off adjusters to relieve preload.
Remove bearing caps and adjusters, then withdraw differential assembly from carrier, making sure side bearing races remain with their respective bearings.
Using puller, (49 0839 425C ) remove side bearings from gear case. Straighten lock tabs, remove ring gear attaching bolts, and separate ring gear from gear case.
On limited slip differentials, gradually loosen attaching screws until distance between left and right half of differential case is about 0.12" (3 mm). Then carefully separate differential halves. Remove following parts: Thrust washer, conical spring, friction plate, friction disc, pressure ring, side gear, pinion gear and spider. Keep parts in order for reassembly. See Figure .
On conventional differentials, drive out differential pinion shaft lock pin with a punch and remove pinion shaft. Rotate pinion gears 90° and remove gears, thrust washer, thrust block (if equipped) and differential side gears.
Remove pinion nut and pinion flange. Remove drive pinion and rear bearing assembly, adjusting shims (if equipped), spacer and bearing collar (if used). Remove front oil seal and withdraw front pinion bearing.
Using a press, remove rear bearing from drive pinion, then lift off pinion adjusting shim. If necessary for replacement, use a drift punch and remove pinion bearing races from carrier.
Inspect all parts for chipped or worn teeth, damaged bearing journals, cracks, flaking or any damage. Replace defective parts as necessary.

NOTE: It may be necessary to tap end of pinion with a soft hammer to remove from carrier.