Disassembly and Assembly

Axle Assembly














Special Tool(s)

Disassembly
1. Remove the differential housing cover and drain the lubricant.
- Clean the gasket material from the differential housing cover and the differential housing.





2. NOTE: An inspection can find the cause of the concern and determine the resolution.

Carry out the following before disassembly.
- Remove all the lubricant from the internal parts of the differential assembly. Visually inspect the parts for wear and damage.
- Rotate the differential assembly to check for any roughness, indicating damaged bearings or gears.
- Check the differential ring gear and pinion teeth for signs of scoring, abnormal wear, nicks and chips.
- Use a magnet to search for heavy metal particles indicating component damage.





3. CAUTION: The differential ring gear and pinion must be clean and dry to obtain an accurate reading.

Using the special tools, measure the differential ring gear and pinion backlash at three equally spaced points.
- The backlash tolerance is 0.13 - 0.20 mm (0.005 - 0.008 inch) and cannot vary more than 0.05 mm (0.002 inch) between points checked. A backlash variation of more than 0.05 mm (0.002 inch) indicates gear/case runout.
- Make corrections for high or low backlash during assembly by changing the differential bearing selective shim thickness.

4. Remove the axle shafts.





5. CAUTION: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps. Matching the letters is important at the time of assembly.

To ease removal of the differential assembly, loosen the bolts, then pry the differential case, bearing cups and outboard spacers outward until they are loose in the differential housing.
6. Remove the bolts and the bearing caps.





7. CAUTION: Do not spread the differential housing more than specified.

Using the special tools, spread the differential housing to the specification. Remove special tool 100-DO02 after spreading the housing.





8. CAUTION: It will be necessary to use large pry bars to remove the differential assembly from the differential housing. Do not damage the differential ring rear when carrying out this step.

CAUTION: Mark or tag the differential bearing cups, indicating from which side they were removed.

Remove the differential assembly with the bearing cups.
- Remove the special tool after removing the differential assembly.
- Inspect the differential bearing cups for deep scores, galling and spalling. Discard them if necessary.





9. CAUTION: Mark or tag the outboard spacers indicating from which side they were removed.

Remove the outboard spacers.
- Inspect the spacers for nicks, bending and grooved conditions. Discard them if necessary.





10. CAUTION: Index-mark the pinion flange to the pinion shaft prior to removal.

Use the special tool to prevent the flange from turning while removing the lock nut and washer.





11. Using the special tool, remove the pinion flange.





12. NOTE: There are drive pinion bearing preload shims and, on Model 70 axles, a preload spacer on the spline-end of the pinion. These shims and spacer can stick to the pinion, the pinion bearing, or they can fall out of the differential housing. Collect and keep the shims and spacer for reassembly.

Using a soft-face hammer, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.





13. Using the special tools, remove and discard the pinion seal.
14. Remove the oil slinger and the pinion bearing.





15. CAUTION: Do not nick the differential housing bore.

Using the special tools, remove the outer pinion bearing cup.
- For Model 60/70 axles, use tools 205-DO54 and 205-DO55.





16. Using the special tools, remove the inner pinion bearing cup.
- For Model 60 axles, use tools 205-DO51 and 205-DO55.
- For Model 70 axles, use tools 205-DO52 and 205-DO55.





17. Using the special tool, remove the inner pinion bearing.

18. NOTE: Discard the drive pinion position shim if bent or nicked. If discarding the shim, measure and record the shim thickness.

Remove the drive pinion position shim.
19. Carry out the following after disassembling the axle:
- Thoroughly clean all parts.
- Inspect all parts for damage and wear.
- Clean the inside of the differential case before assembly.
- Thoroughly clean the differential housing if the gears have scores/chips in them.

Assembly
1. Carry out the Differential Case End Play Check.





2. Position the inner and outer pinion bearing cups and the special tools in their respective differential housing bores.
1 After placing the inner and outer pinion bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup.
2 Place the special tool (outer) on the outer pinion bearing cup.
3 Install the special tool.





3. Tighten the special tool to seat the pinion bearing cups into their bores.





4. CAUTION: Always install new pinion bearings when installing new bearing cups.

NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.

Check that the cups have seated correctly in their bores.











5. CAUTION: If any of the gauge surfaces have nicks in them, remove the high spots with a medium India oilstone to prevent erroneous readings.

NOTE: Apply only a light oil film on the pinion bearings before assembling the tools.

Assemble and position the following in the differential housing.
1 Position the special tool.
2 Position the special tool.
3 Position the inner pinion bearing.
4 Position the special tool.
5 Position the special tool.
6 Position the outer pinion bearing.
7 Thread on the special tool.





6. NOTE: This step simulates pinion bearing preload.

Using a Nm (inch-pound) torque wrench, tighten the special tool to specification.





7. NOTE: Offset the special tool as shown to obtain an accurate reading.

Rotate the special tool several half-turns to seat the pinion bearings and position the special tool as shown.





8. Install the special tool.
1 Position the special tool.
- For Model 60/70 axles, use tool 205-DO33.
- For Model 70TR axles, use tool 205-DO38.

2 Install the bearing caps.
3 Install the bolts.





9. NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring devise.

NOTE: Do not attempt to force the gauge or shim between the special tools. A slight drag indicates a correct selection.

Using a feeler gauge or flat, clean drive pinion position shims, measure between the special tools. Record the measurement. Refer to Pinion Ring Gear Variation Number for shim selection information.
- Remove the special tools after making the correct shim selection.

10. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result

Install the correct thickness drive pinion position shim on the pinion.





11. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.

Using the special tool, an axle bearing/seal plate, and a suitable press, install the pinion bearing.
- For Model 60 axles, use tool 205-092.
- For Model 70 axles, use tool 205-005.

12. NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload. On Model 70 axles, add the thickness of the pinion preload spacer to the thickness of the old drive pinion bearing preload shims.

Inspect the drive pinion bearing preload shims for damage. Discard them if necessary. New shims are available in the thickness shown in the following chart.

Available Drive Pinion Bearing Preload Shims (Model 60/70)




13. CAUTION: The pinion preload spacer must always go on the pinion before the drive pinion bearing preload shims.

On Model 70 axles, assemble the pinion preload spacer onto the pinion.
14. Assemble the drive pinion bearing preload shims onto the pinion, and install the pinion into the differential housing.
15. Install the outer pinion bearing.
16. Install the pinion flange.





17. Use the special tool to prevent the flange from turning while installing the old washer and the lock nut.
- Tighten the nut to 339 Nm (250 ft. lbs.).





18. Using an inch-pound torque wrench, rotate the pinion. The torque must read as specified.
- To increase the preload, remove drive pinion bearing preload shims. To decrease the preload, add shims.





19. If the pinion bearing preload is within specification, and the pinion position shim has changed, change the drive pinion bearing preload shims by the same amount.
- The direction arrow pointing toward the pinion flange indicates that by removing the drive pinion position shim, the distance from the centerline of the tubes to the pinion backface increases, giving a plus (+) reading. The drive pinion bearing preload shim pack does not affect the pinion depth setting. However, if the pinion position is changed, the pinion preload will change and may require adjustment to bring the torque-to-rotate within specification. Arrows on the ring gear illustrate the method to increase or decrease backlash and differential bearing preload.





20. With the drive pinion at the correct preload as determined earlier, remove and discard the lock nut and the washer. Use the special tool to prevent the flange from turning.





21. Using the special tool, remove the pinion flange.





22. Lubricate the pinion seal rubber lips.
- Use Premium Rear Axle Lubricant.

23. Using a suitable driver, install the pinion seal.
- After installation, verify that the garter spring did not pop out of the seal. If the garter spring popped out, install a new pinion seal.





24. Coat the inside of the pinion flange with a small amount of lubricant.
- For Model 60/70 axles, use Premium Rear Axle Lubricant.

25. Install the pinion flange.

26. CAUTION: Always install a new washer and lock nut.

Use the special tool to prevent the flange from turning while installing the new washer and lock nut.
- Tighten the nut to 339 Nm (250 ft. lbs.).

27. Carry out the Ring Gear and Pinion Backlash procedure.
28. Assemble the differential bearing cups to the differential bearings.





29. CAUTION: Do not spread the differential housing more than specified.

CAUTION: Avoid nicking the ring gear teeth and anti-lock speed sensor ring during assembly.

Using the special tools, spread the differential housing to the specification.
- Use a rawhide hammer to seat the differential into the differential housing pocket.
- Remove the special tools.





30. CAUTION: Match the mating letters as noted during disassembly.

Install the bearing caps, aligning the letters with those on the differential housing. Tighten the bolts to specification.





31. Using the special tools, measure the differential ring gear and pinion backlash at three equally spaced points.
- The backlash tolerance is 0.13 - 0.203 mm (0.005 - 0.008 inch) and cannot vary more than 0.05 mm (0.00 - 21 inch) between points checked. A backlash variation of more than 0.05 mm (0.002 inch) indicates gear/case runout.
- Move the differential ring gear toward the pinion to correct high backlash.
- Move the differential ring gear away from the pinion to correct low backlash.
- Moving a specified amount of differential bearing shims from one side of the differential to the other makes these corrections.





32. Confirm the total preload.
- Using an inch-pound torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential case installed) by the amount shown, with new bearings installed as recommended.
- If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.

33. Carry out the Tooth Contact Pattern Check to verify the final pinion position is correct.
34. Install the axle shafts.





35. CAUTION: Clean both flat surfaces (differential housing and differential housing cover) with a suitable solvent to remove all traces of oil film.

CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant.

NOTE: The differential housing cover uses silicone rubber sealant as a gasket.

Apply a continuous bead of silicone sealant, of the specified thickness, to the differential housing cover.
36. Place two bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover.
- Use the two bolts to position the differential housing cover on the differential housing.





37. Install the remaining bolts. Tighten the bolts alternately and evenly.
- Tighten Grade 5 bolts to 47 Nm (35 ft. lbs.).
- Tighten Grade 8 bolts to 61 Nm (45 ft. lbs.).
- Allow 1 -hour cure time before filling the axle with the correct amount of specified lubricant.

38. Fill the axle with the specified type and amount of lubricant.