Differential Assembly: Disassembly

WARNING: This page is about a different car, the 2001 Mazda Tribute. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Extreme care must be taken not to damage aluminum axle housing while carrying out these procedures.

CAUTION: Overspreading can damage axle housing. Maximum spread is .10" (.25 mm).

Using a holding fixture, mount axle housing to a bench. Using a Bearing Cup Remover (308-125), remove halfshaft bearings and seals. Remove bolts and bearing caps. Using Differential Housing Spreader (205-136) and Differential Carrier Spreader (205-001), spread axle housing. Remove differential case and tag bearing cups to indicate which side of carrier they were removed from. Remove tools.
WARNING: Gear teeth have sharp edges. Use care when handling drive pinion. Failure to follow these instructions may result in personal injury.

CAUTION: Ensure drive pinion does not fall out of axle case when drive pinion nut is removed.

NOTE: Drive pinion nut is staked in groove of drive pinion shaft. There may be metal left in groove that must be removed.
Using a Socket, Drive Pinion Nut (205-175) and a Nut Remover (205-503), remove drive pinion nut. Remove drive pinion, collapsible spacer and inner drive pinion bearing. Remove outer drive pinion bearing. Discard collapsible spacer. Using Outer Pinion Bearing Remover (205-249) and Handle (205-153), remove outer drive pinion bearing cup.
CAUTION: Ensure not to damage axle housing when removing inner drive pinion bearing cup.
Remove inner drive pinion bearing cup and oil baffle. Using Pinion and Carrier Puller (205-D036) and Step Plate (205-D016), remove differential case bearing and shims. tag bearing cups and cones together to indicate which side of carrier they were removed from. Discard any damaged shims. Remove and discard bolts. Remove ring gear. Remove differential pinion shaft lock pin and differential pinion shaft. Rotate pinion gears and pinion gear thrust washers to window and remove. Remove side gears and side gear thrust washers. Using pinion and carrier puller and step plate, remove drive pinion bearing and drive pinion position shim.