Differential Carrier Assembly - Disassemble

Differential Carrier Assembly - Disassemble

Tools Required
^ J22912-01 Split-Plate Bearing Puller
^ J2619-01 Slide Hammer with Adapter
^ J29369-1 Bushing and Bearing Remover
^ J29369-2 Bushing and Bearing Remover (2"-3")
^ J42213 Adjuster Sleeve Socket
^ J45224 Side Bearing Adjustment Wrench
^ J45228 Pinion Bearing Cup Remover/Installer
^ J45234 Pinion Remover
^ J8614-01 Flange and Pulley Holding Tool

Inspection Procedure
Perform the following before disassembling the differential carrier assembly:
1. Remove the drain plug from the axle.
2. Drain the axle lubricant.
3. Inspect the oil and the case for metal chips. Determine the source of the metal chips, such as a broken gear or bearing cage.
4. Inspect the ring gear backlash.
5. Measure the rotating torque of the pinion and differential case using an inch-pound torque wrench.
This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and preloading the differential case.
Determine the cause of the axle problem before disassembly, if possible.

Disassembly Procedure





1. Install the J29369-1 (2) and the J2619-01 (1) to the inboard or oil pan side seal as shown.
2. Remove the seal by pulling on the J2619-01 (1).
3. Install the J29369-2 and the J2619-01 to the outboard or wheel drive shaft side seal.
4. Remove the seal by pulling on the J2619-01.





5. Remove the differential carrier case half bolts.
6. Separate the differential carrier case assembly case halves.





7. Remove the differential case assembly.





8. Install the J42213 to the left side differential bearing adjuster.





9. Remove the left side differential bearing adjuster using the J42213.Mark the adjuster.

Important: The differential bearing adjusters are not interchangeable. Mark the adjusters accordingly.






10. Remove the left side differential bearing cup.
11. Install the J45224 to the right side differential bearing adjuster.





12. Remove the right side differential bearing adjuster using the J45224. Mark the adjuster.

Important: The differential bearing adjusters are not interchangeable. Mark the adjusters accordingly.






13. Remove the right side differential bearing cup.





14. Measure the rotating torque of the drive pinion using an inch-pound torque wrench. Record the measurement.





15. Install the J8614-01 to the pinion yoke as shown.
16. Remove the pinion nut while holding the J8614-01.





17. Install the J45234 to the left differential carrier assembly case half as shown.
18. Remove the pinion yoke, the washer, and the drive pinion by turning the screw of the J45234 clockwise.





19. Remove the dust deflector from the pinion yoke with a soft-faced hammer.

20. Remove the pinion oil seal using a suitable seal remover tool.

Important: Carefully pry the seal from the bore. Do not distort or scratch the aluminum case.

21. Remove the outer pinion bearing.





22. Install the J22912-01 between the pinion bearing and the pinion gear as shown.
23. Remove the inner pinion bearing using the J22912-01 and a hydraulic press.
24. Remove the pinion gear selectable shim.





25. Install the J45228-4 to the outer pinion bearing cup as shown.





26. Install the J45228-1 (2) and the J45228-5 (1) to the J45228-4.Seat the ridge of the J45228-1 (2) into the outer pinion bearing cup bore.
27. Remove the outer pinion bearing cup by turning the J45228-5 (1) clockwise.





28. Install the J45228-4 to the inner pinion bearing cup as shown.





29. Install the J45228-1 (1) and the J45228-5 (2) to the J45228-4.
30. Remove the outer pinion bearing cup by turning the J45228-5 (2) clockwise.