Front & Rear (M41 & M59) Differential Assemblies: Disassembly

1. Mount differential carrier into Holding Fixture (J-3289-21) with (J-37769). Place differential carrier and holding fixture into (J-3289-20). Inscribe alignment marks on differential side bearing caps to ensure proper assembly. On rear differentials, remove 2 bolts and side bearing lock plates from side bearing caps. On front differential, remove 2 bolts and side bearing lock plates from differential carrier. On front differential, remove inner air hose. See Figure or Figure .
2. Remove 4 bolts and side bearing caps from differential carrier. Remove side bearing adjusters and bearing races from differential carrier. Remove differential ring gear and case from differential carrier. Turn differential carrier and holding fixture over so that piston flange nut is horizontal. Unstake pinion flange nut. Remove pinion flange nut from pinion gear using Flange Holder (J-8614-01) to hold pinion. Remove pinion gear from differential carrier.
3. On front differential, remove collapsible spacer. Remove pinion seal from differential carrier using Axle Shaft Seal Remover (J-26941) with slide hammer. Remove outer pinion bearing from differential carrier. Remove inner and outer pinion bearing races from differential carrier using a large drift punch and a hammer. Tap around rear of each bearing race slowly drive each race out evenly. Remove side bearings from differential case using Side Bearing Remover (J-22888-D) with Differential Side Bearing Remover Plug (J-8107-4)
4. On front differential, remove actuator. Remove 10 bolts and ring gear from differential case. On (M59) differential , remove 8 bolts. On front differential, remove pinion shaft roll pin. Separate right and left differential case halves. On rear differentials, remove roll pin from right differential case using a hammer and a standard drift punch. See Fig 1 . Disassemble side gears and washers, differential pinion gears and washers and in rear differentials cross shafts and cross shaft joint.
5. Remove inner pinion bearing and collapsible spacer from pinion gear shaft using Rear Bearing Remover (J-22912-01). Place rear bearing remover on pinion gear shaft with concave side toward pinion gear. Place pinion gear in a hydraulic press, and remove inner pinion bearing. Remove pinion selective shim from pinion gear shaft.
   CAUTION: Do not spin dry roller bearings with compressed air. Differential components are set to very close tolerances and are prone to wear should one component fail. In order to ensure accurate adjustment and even wear, ring and pinion gears as well as all tapered roller bearings and races must be replaced as a set.
6. Clean all parts thoroughly with clean solvent and air dry. Inspect differential carrier and case for cracks or stripped threads and repair or replace as necessary. Inspect ring and pinion gears for excessive or unusual wear, cracks, overheating or other damage and replace as necessary. Inspect all roller bearings and races for roughness, locking, or other wear or damage. Replace defective parts as necessary. Inspect side and differential pinion gears for unusual wear or damage. Replace defective parts as necessary.

Fig 1: Removing Roll Pins

Courtesy of SUZUKI OF AMERICA CORP.