This neat little package arrived a while back.


So I cleared out a little room in the shop and pulled the Amigo in.


Start byUnbolting the front drive shaft. Jack up the front end and remove the outer hubs and C-clips on the axles shafts and the front tires. Unbolt the brakes and hang them out of the way. Loosen the upper and lower ball joints on the knuckle, and remove the steering tie rod. For rack and pinion equipped trucks, remove the tierods from the inboard end. It really is easy (scroll down to the pictures).

With the knucles out of the way, drain the differential, remember to drain the CAD (Center Axle Disconnect) if so equipped. If you have a CAD equipped vehicle, remember you will also need to disconnect the vacuum and electrical connectors. You will also need to remove the front crossmember that goes under the differential.

Support the housing on a suitable jack and unbolt the housing from the frame where it is attached with two bolts on each side. Unbolt one of the CV retaining plates and remove the CV shaft. You can now lower the rest of the housing out of the vehicle.

Now you get to dismantle the front housing. Remove the second CV shaft. For the CAD equipped vehicles, you have some extra work to do.

First unbolt the shift actuator(A), and the actuator housing(B) from the differential housing.


Then slide off the sleeve, and the clutch gear, take note of the proper orientation.


Now remove the snapring, holding the bearing and inner shaft in place. It CAN be difficult to get out. In the picture below is the snap ring partially out.


Finally pry out the inner shaft. The third member can now be unbolted and seperated from the front housing.

Mark the bearing caps and ring gear so they can be reinstalled in the same orientation.


With the carrier out of the third member, use a long punch(A) and drive out the lock pin(C) so the cross shaft can be removed(B).


Next using a punch, the internal gears can be removed by gently tapping them out. Be sure to remove all of the thrust washers (one for each gear)but keep the two on the side gears (big flat ones around the splined axles shafts), as you will need them again.


Following the directions install the locker as described in the owners manual. Installation is easy and straight forward. Be sure to note the tolerance as required. Also make sure to keep all dirt and debris out of the diffrential and locker.


At this point reassembly can begin, in the reverse of disassembly.