UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK
Component Disassembly
Page 16-22 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
16
DIFFERENTIAL GEAR CASE DISASSEMBLY
∆ CAUTION
• Mark parts for identification as they are disassembled. Parts must be reassembled in their original
locations and orientations.
1. Remove eight ring gear retaining bolts (72) (Figure 16-51, Page 16-21), and remove the ring gear from
the assembly. It may be necessary to tap the ring gear off with a plastic or rubber mallet (Figure 16-51,
Page 16-21). See following NOTE.
NOTE: Because Loctite was applied to the bolts during assembly, it may be necessary to place the differen-
tial gear case in a vise to remove the bolts.
2. Pull the cover (78) and thrust plate (77) from the differential gear carrier case (Figure 16-48, Page 16-20).
3. Remove the differential gear (81) from the differential gear carrier case (Figure 16-48, Page 16-20).
4. Remove the differential pin (79) (Figure 16-48, Page 16-20) by pushing it through from one side (Fig-
ure 16-52, Page 16-22). Remove the two differential idler gears (80) and two idler gear thrust plates
(76) (Figure 16-4, Page 16-4) as the pin is driven through. See following NOTE.
NOTE: It may be necessary to drive the differential pin out with a hammer and punch.
5. Remove the differential gear (82) from the carrier case (Figure 16-48, Page 16-20).
6. If the bearings (70 and 71) are to be removed, place a bearing puller wedge attachment (CCI 1012812)
between the bearing and gear case (75) (Figure 16-48, Page 16-20) and press the bearing off as
shown (Figure 16-53, Page 16-22). Repeat the process for the bearing (70) on the carrier cover (78)
(Figure 16-48, Page 16-20). See following CAUTION.
∆ CAUTION
• Do not tighten the bearing puller wedge attachment against the shaft. This could damage the shaft.
Figure 16-52 Differential Pin
Figure 16-53 Remove Bearing
ARBOR
PRESS
RAM
WEDGE
ATTACHMENT
