DRIVE-FINAL
DISASSEMBLY
1. Remove the roll pin using a pin punch (1).
2. Discard the old roll pin (3).
3. Remove the pinion shaft (2) and inspect for excessive ware.
4. Roll the pinion gears (3) and shims (1) out of the carrier (2).
5. Remove the pinion gear shims (1) and mark for installation.
6. Remove the pinion gears (1) from the carrier (3).
7. Remove the side gears (2) and shims (3) from the carrier.
8. If the vehicle is a two wheel drive remove the carrier bearings using Puller C-293 PA, six Inserts C-293-40 and Press Insert C-4996.
9. If all wheel drive use Puller C-293 PA, six 9613 inserts and Press insert 8888 to remove the carrier bearings.
10. Remove the nut (1) on the reduction gear (2).
11. Press the shaft of the small gear (1) using Button 8923 (2), a Press and Blocks to remove from large gear (4).
12. Remove the small side reduction gear bearing (4) using Splitter 1126 (1), Button 8923 (2) and a Press.
ASSEMBLY
WARNING: Use welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.
CAUTION: A bearing heater is used to assembly some components. Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 177 Celsius (212 deg Min. - 350 deg Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.
1. A bearing heater may be used in place of a installer.
2. Install small gear and shaft (3) onto large gear (4).
3. Using installer L-4507 (1) or a bearing heater, install the bearing (2) onto the shaft.
4. Using installer L-4507 (1) or a bearing heater install the small gear side bearing onto the shaft.
5. Install the new reduction gear nut and tighten to 250 N·m (184 ft. lbs.)
6. For two wheel vehicles use Installer C-3716 A and Handle C-4171 or a bearing heater to install the bearings onto the carrier (both sides). Use installer 9333-2 or a bearing heater on the big bearing and Installer C-3716 A and Handle C-4171 on the small bearing for four wheel drive vehicles.
7. Install the side gears (2) and shims (3) onto the carrier.
8. Place the pinion gears (3) onto the side gears with the correct shims (1).
9. Roll into place.
10. Install the pinion shaft (2).
11. Use a new roll pin (3).
12. Install the roll pin (3) using a pin punch (1).