Differential

DIFFERENTIAL / DISASSEMBLY








1. Remove differential bearing cones (ring gear and diff. case side) using Tool C-293-PA, Adapters C-293-45, and Tool 4996 (Fig. 75) (Fig. 76).





2. Remove ring gear-to-case bolts (Fig. 77). Discard and use NEW bolts upon assembly.








3. Using a suitable screwdriver, pry off speedometer drive gear (Fig. 78) (Fig. 79).








4. Using hammer and suitable punch, remove pinion shaft retaining pin (Fig. 80) (Fig. 81).





5. Remove pinion shaft (Fig. 82).








6. Remove pinion gears, side gears, and thrust washers (Fig. 83) (Fig. 84).

ASSEMBLY
1. Assemble side gears, pinion gears, and thrust washers (Fig. 84) into case through opening and rotating into position (Fig. 83).
2. Install pinion shaft (Fig. 82).





3. Using hammer and suitable punch, install pinion shaft retaining pin (Fig. 85).





4. Stake case to retain pin as shown in (Fig. 86).








5. Using an arbor press, Handle C-4171, and Tool L-4410, install differential side bearings to ring gear and case side (Fig. 87) (Fig. 88).





6. Install speedometer drive gear to case (Fig. 89).








7. Using an arbor press, steel block, and Tool L-4440, press speedometer drive gear onto differential case (Fig. 90) (Fig. 91).





8. Install ring gear to differential case. Install new bolts and torque to 81 Nm (60 ft. lbs.) torque (Fig. 92).


Measure and Adjust Side Gear End-Play








1. Rotate the assembly two full revolutions both clockwise and counter clockwise. Set up dial indicator as shown and record end play (Fig. 93) (Fig. 94). Rotate side gear 90 degrees and take another measurement. Again, rotate side gear 90 degrees and record a final measurement.
2. Using the smallest end play recorded, shim that side gear to within 0.001 to 0.013 inch. The other side gear should be checked using the same procedure.

CAUTION: Side gear end play must be within 0.001 to 0.013 inch. Five select thrust washers are available: 0.027, 0.032, 0.037, 0.042, and 0.047 inch.