Differential Replacement

Differential Replacement

Tools Required
^ J34178Spreader Gage Adapter
^ J45222 Axle Housing Spreader
^ J8001 Dial Indicator Set

Removal Procedure

Important: Group and mark the shims together as originally removed. If you remove or replace the ring and pinion gearset, perform the bearing preload, backlash, and gear tooth contact pattern check in order to ensure proper contact of the gears. If you reinstall or replace the differential assembly without replacing any other component (i.e. pinion and ring gear set, bearings. etc.) then you may reinstall the assembly with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the differential assembly.

1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the rear axle tie rod.

3. Important: If the differential assembly is to be re-installed, install the thrust block and the thrust block lock bolt after removing the axle shafts in order to retain the alignment of the differential gears.

Remove the axle shafts.
4. Loosen the bearing cap bolts. Do not remove the bearing cap bolts at this time.





5. Install the J45222 onto the axle housing as shown.





6. Install the J8001-1 (2), the J8001-2 (3), the J34178 (4, 6), and the J8001-3 (5) as shown.
7. Preload the J8001-3 (5) approximately 3/4 of a turn clockwise.
8. Rotate the indicator housing to align the indicator needle of the J8001-3 (5) and the dial indicator face to ZERO.
9. Spread the axle housing by turning the clevis screw of the J34178 while observing the J8001-3. Spread the housing just enough to remove the differential assembly. Do not spread the housing more than 1.02 mm (0.040 inch).





10. Remove the bearing caps bolts and the caps. Mark the bearing caps left and right.

11. Caution: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.

Notice: When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.

Remove the differential assembly from the axle housing.
12. Remove the bearing cups, the shims, and the spacers as necessary. Mark the cups and shims left and right and in the proper order as necessary. Place the cups and the shims with the bearing caps.
13. Remove the J8001-1, the J8001-2, the J34178, and the J8001-3.
14. Remove the J45222.
15. Remove the differential side bearings, if necessary.
16. Remove the ring gear, if necessary.

Installation Procedure
1. Install the ring gear, if necessary.
2. Install the differential side bearings, if necessary.
3. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations.





4. Install the J45222 onto the axle housing as shown.





5. Install the J8001-1 (2), the J8001-2 (3), the J34178 (4, 6), and the J8001-3 (5) as shown.
6. Preload the J8001-3 (5) approximately 3/4 of a turn clockwise.
7. Rotate the indicator housing to align the indicator needle of the J8001-3 (5) and the dial indicator face to ZERO.
8. Spread the axle housing by turning the clevis screw of the J34178 while observing the J8001-3. Spread the housing just enough to install the differential assembly. Do not spread the housing more than 1.02 mm (0.040 inch).





9. Place the differential assembly, with the bearing cups installed, into the axle housing. Support the differential assembly in order to keep the assembly from falling out of the axle housing.





10. Install the bearing caps and the bolts. Do not torque the bearing cap bolts at this time.
11. Adjust the differential side bearing preload. Refer to Differential Side Bearing Preload Adjustment (9.5 Inch Axle).
12. Adjust the backlash. Refer to Backlash Adjustment.
13. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection.

14. Notice: Refer to Fastener Notice in Service Precautions.

Tighten the bearing cap bolts.

Tighten the bearing cap bolts to 75 Nm (55 ft. lbs.).





15. Remove the thrust block lock bolt.





16. Remove the thrust block.
17. Install the axle shafts.
18. Install the rear axle tie rod.
19. Lower the vehicle.