Section 5 (Rear Driveline Module): Disassembly: Disassembly

Fig 1: Electric Clutch AT Rear Axle

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1. Remove the four bolts (1) holding the rear axle electric clutch. Refer to Fig 1.
2. Separate the rear axle electric clutch from the rear axle.
   Fig 2: Bolts AT Rear Axle

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3. Remove the differential case bolts (1).
4. Remove the cap bolts (2).
5. Remove differential cover and both axle seals.
   Fig 3: Carrier AT Rear Axle

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   NOTE:

   There are select shims at each side of the carrier.

6. Remove the carrier (1) from the differential housing (2).
7. Measure the select shims on each side of the carrier roller bearings and note for installation.
   Fig 4: Ring Gear Bolts

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8. Remove the ring gear bolts (1).
9. Remove the ring gear (2).
   Fig 5: Roll Pin

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10. Remove roll pin (1) in carrier case (2) and through the pinion mate shaft (4) using a punch (3).
    Fig 6: Spider And Side Gears

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11. Remove spider gears (3), thrust washers (4) and side gears (2).
    Fig 7: Remove Carrier Bearings

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12. Remove carrier bearings (3) using Splitter (special tool #1130, Splitter, Bearing/Gear) (4), Installer (special tool #9643, Installer, Bearing) (2) and a press (1).
    Fig 8: Remove Pinion Seal

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13. Use a screw driver to remove the pinion seal.
    Fig 9: Pinion Nut On And Off

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14. Remove pinion retaining nut using Spline Holder (special tool #9742, Splined Socket) (1) and Socket (special tool #9921, Wrench, Pinion Nut) (2).
    Fig 10: Remove Pinion

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15. Tap pinion (3) with a soft hammer (1) to remove from case (4).
    Fig 11: Outer Pinion Bearing Cup

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16. Using a hammer (4) and a punch (1) remove the outer pinion bearing cup (2).
    Fig 12: Pinion Head Bearing Cup

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17. Using a hammer (4) and a punch (2) remove the pinion head bearing cup (1).
    Fig 13: Outer Pinion Bearing

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18. Remove collapsible spacer (2) from the pinion shaft (1).
    Fig 14: Removing Pinion Bearing Using Puller And Adapters

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19. Remove the pinion bearing (3) using Puller (special tool #C-293-PA, Puller, Press) (1) and Adapters (special tool #C-293-45, Block Set, Puller) (2).