Differential Overhaul

9-3/4 INCH RING GEAR AXLE

1. Remove differential bearing cups and tag for assembly reference.
2. Secure differential in a suitable vise and drive out pinion shaft lock pin.
3. Remove differential bearing cone and roller using a suitable puller and plug No. J-8107-3. Tag cone and rollers for assembly reference.
4. Remove spacer, pinion shaft, pinions, side gears and thrust washers from differential case.
5. Remove ring gear attaching bolts and the ring gear.
6. Position differential side gears and new thrust washers in differential case.
7. Position differential pinions and new thrust washers in differential case.
8. Install pinion shaft in case, then align hole in shaft with hole in case and drive lock pin into position. Peen hole to prevent pin from falling from case.
9. Install ring gear and tighten bolts alternately and evenly to 110 ft. lbs.
10. Position side bearings onto case and seat bearings using a suitable driver.
11. Determine total amount of shims needed to set backlash as follows:
a. Place differential case in carrier and install bearing caps in original position. Tighten caps just enough to retain in place.
b. Install dial indicator on carrier with indicator button contacting back surface of ring gear.
c. Rotate differential case and note runout. If runout exceeds .002 inch, remove differential case and the ring gear from case.
d. Reinstall case and check runout at case flange. If runout exceeds .002 inch, the bearing or differential case is defective and corrections should be made before proceeding.
e. Position two screwdrivers between bearing cup and ring gear on opposite side of ring gear. Apply force to screwdrivers to move differential case as far as possible toward dial indicator. Rock the ring gear to seat bearings and, with force still applied, set dial indicator to ``0.''
f. Reposition screwdrivers between bearing cup and carrier on ring gear side. Apply force to screwdrivers to move differential case as far as possible toward center of carrier and note indicator readings.
g. Remove differential case from carrier.

10-1/2 INCH RING GEAR AXLE

1. Remove differential side bearings using a suitable puller or press.
2. Remove ring gear attaching bolts and the ring gear.
3. Scribe an alignment mark on both case halves, then remove bolts holding case halves together.
4. Tap top half of case loose from bottom, then remove top half and all internal components.
5. Position new washers on side gears, using a small amount of lubricant on side gear hubs.
6. Install pinion gears and new washers onto cross shaft.
7. Assemble top half of case to bottom half, using alignment marks made during disassembly. Tighten bolts alternately and evenly.
8. Install ring gear and tighten bolts alternately and evenly to 110 ft. lbs.
9. Position side bearings onto case and seat bearings using a suitable driver. When installing second bearing, support case with suitable pilot to prevent damaging case of opposite bearing.
10. Determine side bearing shim requirements as follows:
a. Place bearing cups over side bearings and install differential case into carrier, with pinion removed from carrier.
b. Position original shim in ring gear side, then install bearing caps and tighten just enough to retain in place.
c. Install a dial indicator on carrier with indicator button contacting back surface of ring gear.
d. Position two screwdrivers between bearing shim and carrier on ring gear side of case. Apply force to screwdrivers to move differential case as far as possible away from dial indicator. With force still applied, set dial indicator to ``0.''
e. Reposition screwdrivers on opposite side of differential case and force differential case back toward dial indicator. Repeat sequence several times until same reading is obtained.
f. Add thickness of shim to dial indicator reading and record the result.