Overhaul

Differential Overhaul

Disassembly Procedure

1. Remove the differential side bearings. Refer to Differential Bearing Replacement ().





Note: The ring gear bolts have left-hand threads.

2. Remove and discard the ring gear bolts.





Caution: Do not pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.

Note: It maybe necessary to use a brass drift and a hammer to remove the ring gear.

3. Remove the ring gear from the differential case.




4. Mark the pinion gears top (8) and bottom and the differential side gears (6) left and right.
5. Remove the pinion shaft lock bolt (2).
6. Remove the pinion shaft (1).

Note: Roll the differential pinion gears (8) and the thrust washers (7) out of the differential case (3).

7. Remove the differential pinion gears (8) and the thrust washers (7) from the differential case (3).
8. Remove the differential side gears (6), thrust washers (5) and the preload springs (4).

Assembly Procedure




1. Using the proper axle lubricant, lubricate the pinion (8) and side gears (6). Refer to Fluid and Lubricant Recommendations (Maintenance).

Note: If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to their original locations.

2. Install the differential side gears (6), thrust washers (5) and the preload springs (4) into the differential case (3).
3. Position one pinion gear (8) between the differential side gears (6).

Note: Install the second differential side gear directly opposite of the first gear.

4. Position the second pinion gear (8) between the differential side gears (6).
5. Rotate the differential side gears (8) until the pinion gears is directly opposite the opening in the differential case.

Note: Rotate the pinion gears toward the differential opening in order to permit the sliding in of the thrust washers.

6. Install the thrust washers (7).
7. Install the pinion shaft (1).

Caution: Refer to Fastener Caution (Fastener Caution).

8. Install and tighten new pinion shaft lock bolt (2) to 25 Nm (18 lb ft).





Note: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

9. Install the ring gear to the differential case.





Note:
* The ring gear bolts have left-hand threads.
* Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

10. Install the new ring gear bolts.

Note: Tightening the ring gear bolts in sequence will seat the ring gear evenly on the differential case.

11. Tighten the ring gear bolts in sequence to 130 Nm (96 lb ft).
12. Install the differential side bearings. Refer to Differential Bearing Replacement ().