Disassembly and Assembly - Standard

REMOVAL
1. Remove differential housing cover and drain lubricant from the housing.
2. Remove hub bearings and axle shafts.





3. Remove adjuster lock bolts and adjuster locks (Fig. 31).
4. Mark bearing caps left and right for installation reference.
5. Remove bearing cap bolts and remove bearing caps.





6. Loosen differential bearing adjusters (Fig. 32) with Spanner Wrench 8883.
7. Remove differential case from the housing.
8. Remove bearing cups and tag them left and right for installation reference.

DISASSEMBLY
1. Remove pinion shaft lock bolt.





2. Remove pinion shaft (Fig. 33).





3. Rotate differential pinion gears to differential window and remove pinion gears and thrust washers (Fig. 34).





4. Remove differential side gears and thrust washers (Fig. 35).

ASSEMBLY

NOTE: If the same gears and thrust washers are being used, install them into their original locations.

1. Lubricate all differential components with axle lubricant.





2. Install differential side gears and thrust washers (Fig. 36).





3. Rotate the one pinion gear with thrust washer into the differential case (Fig. 37). Then rotate the other pinion gear with thrust washer into the differential case.
4. Align hole in the pinion gears with hole in the differential case.
5. Install pinion shaft.
6. Install new pinion shaft lock bolt and tighten to 52 Nm (38 ft. lbs.).

INSTALLATION
1. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth.

CAUTION: Do not use water, steam, kerosene or gasoline for cleaning.

2. Lubricate differential case bearing.
3. Install differential case with bearings cups into the housing.





4. Install bearing caps and bolts (Fig. 38). Tighten the bearing cap bolts finger-tight.

NOTE: Do not torque bearing cap and bolts at this time.

5. Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained.
6. Holding the differential case toward the pinion gear, turn bearing adjusters with Spanner Wrench 8883 until they make contact with the differential bearings/cups.
7. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash.
8. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
9. Tighten pinion gear side adjuster firmly against the differential case bearing cup.
10. Rotate the pinion several times to seat the differential bearings.
11. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup.
12. Tighten pinion gear side adjuster until it just makes contact with the bearing cup.
13. Tighten pinion gear side adjuster an additional:
^ New Bearings: 6 Adjuster Holes
^ Original Bearings: 4 Adjuster Holes

14. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
15. Tighten bearing cap bolts to 85 Nm (63 ft. lbs.).





16. Tighten adjuster lock bolts to 25 Nm (18 ft. lbs.) (Fig. 39).
17. Measure ring gear backlash and check gear tooth contact pattern.
18. Install axle shafts and hub bearings.
19. Install differential housing gasket and cover. Tighten cover bolts to 40 Nm (30 ft. lbs.).
20. Fill differential with lubricant.
21. Install fill plug and tighten to 32 Nm (24 ft. lbs.).