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Transfer Case - NV242: Disassembly: Differential

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.
  1. Mark differential case halves for reference.
  2. Remove differential case bolts.
  3. Invert differential on workbench.
  4. Separate top case from bottom case. Use slots in case halves to pry them apart. See Fig 1.
  5. Remove thrust washers and planet gears from case pins. See Fig 2.
  6. Remove mainshaft and sprocket gears from bottom case. See Fig 3. Note gear position for reference before separating them.
Fig 1: Separating Differential Case Halves
GC0017438Courtesy of DAIMLERCHRYSLER CORP.
1 - TOP CASE
2 - CASE BOLTS
3 - CASE BOLTS
4 - CASE SLOTS
5 - CASE BOLTS
Fig 2: Planet Gears And Thrust Washer Removal
GC0017439Courtesy of DAIMLERCHRYSLER CORP.
1 - BOTTOM CASE
2 - THRUST WASHERS (12)
3 - PLANET GEARS (6)
Fig 3: Mainshaft Gear And Sprocket Gear Removal
GC0017440Courtesy of DAIMLERCHRYSLER CORP.
1 - MAINSHAFT GEAR
2 - SPROCKET GEAR
3 - BOTTOM CASE
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