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Final Drive: Disassembly

Fig 1: Differential Cover Bolts
GC0000739Courtesy of DAIMLERCHRYSLER CORP.
1 - DIFFERENTIAL COVER BOLTS
2 - DIFFERENTIAL COVER
NOTE: The transfer shaft should be removed for differential repair and bearing turning torque checking.
  1. Remove the differential cover and bolts (1). See Fig 1.
    Fig 2: Differential Retainer Bolts
    GC0000741Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL RETAINER BOLTS
  2. Remove the differential bearing retainer bolts (1). See Fig 2.
    Fig 3: Removing Bearing Retainer
    GC0000742Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL BEARING RETAINER
    2 - HOLDER L-4435
  3. Remove the differential bearing retainer (1) using Holder L-4435 (2). See Fig 3.
    Fig 4: Checking Side Gear End Play (Extension Housing Side)
    GC0020579Courtesy of DAIMLERCHRYSLER CORP.
    1 - ADAPTOR C-4996 (NOTE POSITION)
    2 - DIAL INDICATOR SET
    3 - DIFFERENTIAL ASSEMBLY
    4 - SIDE GEAR
  4. Using a plastic hammer, remove extension housing/adapter plate on the right side of the transaxle.
    WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY TO PREVENT IT FROM ROLLING OUT OF HOUSING.
  5. Remove differential assembly.
  6. Set up Dial Indicator Set C-3339 (2) and Adapter C-4996 (1) to measure side gear end play (Extension Housing Side). See Fig 4.Side gear end play must be within 0.001-0.013 in. 
    Fig 5: Checking Side Gear End Play (Ring Gear Side)
    GC0020580Courtesy of DAIMLERCHRYSLER CORP.
    1 - ADAPTOR C-4996 (NOTE POSITION)
    2 - DIAL INDICATOR SET
    3 - DIFFERENTIAL ASSEMBLY
  7. Set up Dial Indicator Set C-3339 (2) and AdapterC-4996 (1) to measure side gear end play (Ring Gear Side). See Fig 5. Side gear end play must be within 0.001-0.013 in. 
    Fig 6: Button L-4539-2 and Collets 5048-4
    GC0020594Courtesy of DAIMLERCHRYSLER CORP.
    1 - COLLETS 5048-4
    2 - BUTTON L-4539-2
    3 - BEARING CONE
  8. Remove differential side bearing cone (3) from ring gear side of differential. Install button L-4539-2 (2), and Collets 5048-4 (1). See Fig 6.
    Fig 7: Side Bearing Removal Using Tool 5048 (Ring Gear Side)
    GC0020593Courtesy of DAIMLERCHRYSLER CORP.
    1 - PULLER SET 5048
    2 - COLLETS 5048-4
    -
  9. Install Puller Set 5048 (1), collets 5048-4 (2) and sleeve. Remove and discard bearing cone. See Fig 7.
    Fig 8: Install Button L-4539-2
    GC0020591Courtesy of DAIMLERCHRYSLER CORP.
    1 - BUTTON L-4539-2
  10. Remove differential side bearing cone from outboard end (opposite ring gear) of differential. Install Button L-4539-2 (1). See Fig 8.
    Fig 9: Side Bearing Removal Using Tool 5048
    GC0020592Courtesy of DAIMLERCHRYSLER CORP.
    1 - PULLER SET 5048
    2 - COLLET 5048-3
    -
  11. Install Puller Set 5048 (1), (2) collets 5048-3 and sleeve. Remove and discard bearing cone. See Fig 9.
    Fig 10: Pinion Shaft Retainer
    GC0020588Courtesy of DAIMLERCHRYSLER CORP.
    1 - PINION SHAFT RETAINER
  12. Remove pinion shaft retainer plate bolts (1). See Fig 10.
    Fig 11: Pinion Shaft Retainer
    GC0020587Courtesy of DAIMLERCHRYSLER CORP.
    1 - PINION SHAFT RETAINER
  13. Remove pinion shaft retainer (1). See Fig 11.
    Fig 12: Pinion Shaft Removal/Installation
    GC0020586Courtesy of DAIMLERCHRYSLER CORP.
    1 - PINION SHAFT
  14. Remove pinion shaft (1) from differential case. See Fig 12.
    Fig 13: Pinion Gear and Washer
    GC0020585Courtesy of DAIMLERCHRYSLER CORP.
    1 - WASHER
    2 - PINION GEAR
  15. Rotate pinion gears (2) about case and remove (w/washer) (1). See Fig 13.
    Fig 14: Side Gear Removal/Installation
    GC0020583Courtesy of DAIMLERCHRYSLER CORP.
    1 - SIDE GEAR
  16. Remove differential side gears (1). See Fig 14.
    Fig 15: Side Gear Washer
    GC0020584Courtesy of DAIMLERCHRYSLER CORP.
    1 - SIDE GEAR THRUST WASHER
  17. Remove side gear thrust washers (1). See Fig 15.
    Fig 16: Ring Gear Bolt Removal/Installation
    GC0020582Courtesy of DAIMLERCHRYSLER CORP.
    1 - RING GEAR BOLTS
  18. Remove remaining differential ring gear-to-case bolts (1). See Fig 16.
    Fig 17: Ring Gear Removal
    GC0020581Courtesy of DAIMLERCHRYSLER CORP.
    1 - SOFT-FACED HAMMER
    2 - RING GEAR
  19. Using a soft-faced hammer (1), remove ring gear (2) from case. See Fig 17.
    Fig 18: Position Bearing Cup Remover Tool In Retainer
    GC0000746Courtesy of DAIMLERCHRYSLER CORP.
    1 - JAW SET 6062A
    2 - DIFFERENTIAL BEARING RETAINER
  20. Using Jaw Set 6062A, remove the differential bearing race from the extension housing/adapter plate. See Fig 18.
    Fig 19: Removing Bearing Cup
    GC0000747Courtesy of DAIMLERCHRYSLER CORP.
    1 - JAW SET 6062A
    2 - DIFFERENTIAL BEARING RETAINER
  21. Using Jaw Set 6062A, remove the differential bearing race from the bearing retainer. See Fig 19.
DIFFERENTIAL SERVICE TOOLS

COMPONENT REMOVER INSTALLER
Diff. Bear. On Retainer Side 5048, 5048-4 Collets, L-4539-2 Button 5052, C-4171
Diff. Bear. On Ext. Hous. Side 5048, 5048-3 Collets, L-4539-2 Button L-4410, C-4171
Diff. Race. On Retainer Side 6062-A 6061, C-4171
Diff. Race. On Ext. Hous. Side L-4518 L-4520, C-4171
Extension Housing Seal 7794-A, C-637 Slide Hammer L-4520, C-4171
Bearing Retainer Seal 794-A, C-637 Slide Hammer L-4520, C-4171
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