Final Drive: Disassembly

The valve body and solenoid wiring connector must be removed from the transaxle in order to service the transaxle differential. The transfer shaft cannot be removed with the valve body in place. Remove the valve body assembly from the transaxle. (Refer to VALVE BODY )

1. Remove transfer chain cover. See Fig 1.
   Fig 1: Removing Chain Cover

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2. Remove chain oiler. See Fig 2.
   Fig 2: Removing Chain Oiler

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3. Remove chain snubber. See Fig 3.
   Fig 3: Removing Chain Snubber

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4. Remove output shaft sprocket snap ring and wave washer. See Fig 4.
   Fig 4: Removing Output Shaft Sprocket Snap Ring & Wave Washer

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5. Remove transfer shaft sprocket snap ring and wave washer. See Fig 5.
   Fig 5: Removing Transfer Shaft Sprocket Snap Ring & Wave Washer

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   CAUTION: The chain sprockets have a slip fit onto their shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly removal or installation will be difficult. Overspreading of the chain sprocket will also make sprocket removal difficult.
6. Install chain spreader 6550 and expand to facilitate sprocket and chain removal. See Fig 6.
   Fig 6: Installing Chain Spreader

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7. Remove chains and sprockets as an assembly. See Fig 7.
   Fig 7: Removing Chains & Sprockets As An Assembly

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   CAUTION: To ensure proper gear ratio, verify that the correct chain and sprocket ratio is selected.
   CAUTION: When reinstalling drive chains, the blue link must face outward.
8. Using suitable snap ring pliers, remove long stub shaft snap ring. See Fig 8.
   Fig 8: Removing Long Stub Shaft Snap Ring

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9. Using slide hammer C-3752 and remover 8420A, remove long stub shaft from transaxle. See Fig 9.
   Fig 9: Removing Long Stub Shaft

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   CAUTION: Driveshaft retainer clips and seals located on the stub shafts must be replaced before reinstalling halfshafts.
10. Remove inner differential adjuster lock. See Fig 10.
    Fig 10: Removing Inner Differential Adjuster Lock

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11. Remove differential outer adjuster lock. See Fig 11.
    Fig 11: Removing Outer Adjuster Lock

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12. Loosen outer adjuster. See Fig 12.
    Fig 12: Loosening Outer Adjuster

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13. Remove differential side cover, and carrier/ring gear assembly. See Fig 13. If differential disassembly is not required, refer to Step 14.
    Fig 13: Removing Differential Side Cover, Carrier & Ring Gear Assembly

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    DIFFERENTIAL DISASSEMBLY

    1. Remove ring gear-to-carrier bolts. See Fig 14.
       Fig 14: Removing Ring Gear Bolts

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    2. Using a plastic or soft-tipped hammer, tap ring gear off of carrier. See Fig 15.
       Fig 15: Tapping Off Ring Gear

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    3. Using suitable pry tools, pry differential carrier apart. See Fig 16.
       Fig 16: Prying Differential Carrier Apart

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    4. Remove stub shaft C-clip. See Fig 17.
       Fig 17: Removing C-Clip

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    5. Using a suitable punch, remove pinion shaft roll pin. See Fig 18.
       Fig 18: Removing Pinion Shaft Roll Pin

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    6. Remove differential pinion shaft. Remove pinion and side gears. See Fig 19.
       Fig 19: Sliding Out Differential Pinion Shaft & Removing Pinion Gears & Side Gears

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    7. Using tool C-293-PA, adapters C-293-48, and adapter C-4996, remove differential carrier bearings. See Fig 20.
       Fig 20: Removing Carrier Bearing

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14. Remove inner adjuster. See Fig 21.
    Fig 21: Removing Inner Adjuster By Turning Clockwise

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15. Remove differential vent baffle. See Fig 22.
    Fig 22: Removing Differential Vent Baffle

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    CAUTION: Failure to grind and open stakes on the transfer shaft nut will result in thread damage to transfer shaft during nut removal.
    WARNING: Wear safety goggles while grinding stake nuts.
16. Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nut as shown in Fig 23 and Fig 24 . Do not grind through the transfer shaft nut into the shaft. There are two stakes on the nut.
    Fig 23: Grinding Stakes

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    Fig 24: Identifying Stake Grinding Pattern

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17. Using a small chisel, carefully open stakes on nut. See Fig 25)
    Fig 25: Opening Nut Stakes

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18. Remove the transfer shaft nut. See Fig 26.
    CAUTION: Do not  reuse old transfer shaft nut because the removed stake weakens the nut flange.
    CAUTION: The transfer shaft cannot be removed from the case at this time.
    Fig 26: Pressing Transfer Shaft Downward To Remove Rear Cone

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19. Install special tool 6577 to remove rear transfer bearing cup. See Fig 27.
    Fig 27: Removing Transfer Bearing Cup

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20. Remove transfer shaft preload shim. See Fig 28. If transfer shaft bearings are to be reused, the original shim must also be reused.
    Fig 28: Removing Preload Shim

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21. Remove transfer shaft assembly from case. See Fig 29.
    Fig 29: Removing Transfer Shaft Assembly From Case

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    CAUTION: If the transfer shaft is removed from the transaxle case for any reason, both seals must be replaced.
22. Remove transfer shaft seals using special tool 6310 and foot 6310-9. See Fig 30. Do not reuse old seals. The seals will be pulled out the rear of the case.
    Fig 30: Identifying Transfer Shaft Seal Remover

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23. Remove the front transfer shaft bearing cup using special tool 6495 and handle C-4171. See Fig 31. Use a press with special tools to remove cup.
    Fig 31: Removing Front Transfer Shaft Cup

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24. Support special tool P-334 on press table so that pinion head of transfer shaft can be pressed through table. See Fig 32.
    Fig 32: Removing Front Transfer Shaft Bearing & Pinion Depth Shim

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