Rear Differential Disassembly and Reassembly (4WD): Disassembly

NOTE:  Refer to the Exploded View as needed during the following procedure.

• 1. Oil Filler Plug and Drain Plug - Remove

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  1. Remove the drain plug (A) with the sealing washer (B)

  2. Remove the oil filler plug (C) with the sealing washer (D).

• 2. Companion Flange - Remove

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  1. Pry up the stake on the locknut (A) from the groove of the differential clutch assembly, making sure the tab completely clears the groove to prevent damaging the differential clutch assembly.

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  2. Install the companion flange holder and the holder handle on the companion flange.

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  3. Loosen the locknut (A) counterclockwise so its tab (B) comes out from the groove (C) in the differential clutch assembly.

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  4. Tighten the locknut (A) until its tab (B) aligns with the groove (C) 5. Clean any dirt from inside the groove in the differential clutch assembly, then loosen the locknut.

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  6. Remove the locknut (A), the spring washer (B), the backup ring (C), the O-ring (D), and the companion flange (E).

• 3. Torque Control Differential Case - Remove

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  1. Remove the eight mounting bolts (A) in a crisscross pattern in several steps

  2. Remove the torque control differential (TCD) case (B) and the 6 x 10 mm dowel pins (C).

• 4. Differential Clutch Assembly - Remove

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  1. Remove the 30 mm shim (A)

  2. Remove the differential clutch assembly (B).

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  3. Remove the six steel balls (A) and the base cam (B) 4. Remove the thrust needle bearings (C) and the pressure plate (D).

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  5. Remove the oil pump driveshaft (A).

• 5. Oil Pump Body Assembly - Remove

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  1. Remove the three mounting bolts (A) and the oil pump body assembly (B)

  2. Remove the oil pump pin (C), the 8 x 10 mm dowel pins (D), the magnet (E), and the fluid strainer (F).