Differential & Drive Pinion Removal

Using INCH-lb. torque wrench, measure and record differential total preload. See Fig 1. Remove left differential bearing retainer. Ensure case or retainer is not damaged if prying is necessary.
On A-540E and A-541E transaxles, remove right bearing retainer. On all transaxles, remove carrier cover bolts in crisscross pattern. Remove cover. Remove apply port gasket at lower portion of case. Remove differential assembly.
From converter side of case, remove drive pinion cap. Using INCH-lb. torque wrench, measure drive pinion preload. See Fig 1. Starting preload should be 4.3-6.9 INCH lbs. (.5-.8 N.m). Subtract drive pinion preload from total preload.
If difference is not 1.1-1.7 INCH lbs. (about .1 N.m), differential side bearing preload may not have been within specification. Carefully inspect condition of all bearings and replace as needed. See appropriate component disassembly and reassembly procedure under OVERHAUL.
Bend back locking washer securing nut on drive pinion shaft. Secure driven gear and remove nut. Using appropriate puller, remove driven gear and bearing. Using appropriate 2-jaw puller, remove outer race, spacer and oil slinger. On A-540E transaxle, remove sensor rotor.
On all transaxles, remove snap ring. Turn transaxle case, converter side facing up. Install appropriate bar into hole in drive pinion. Press out drive pinion shaft. Remove bearing cage from drive pinion. Press off bearing if replacement is needed.

Fig 1: Checking Driven Pinion Preload Or Total Preload