Differential Case and Ring Gear
Differential Case and Ring Gear
Special Tool(s)
Disassembly
All differentials
1. NOTE: Differential bearing shims are available in thicknesses of 0.762, 0.787, 0.813, 0.838, 0.864, 0.889 and 0.914 mm (0.030, 0.031, 0.032, 0.033, 0.034, 0.035 and 0.036 inch).
NOTE: If damaged, install new differential bearing shims.
NOTE: Install new differential bearings if removing them from the differential case.
Using the special tool, remove the differential bearings.
^ Wire the differential bearing shims, differential bearing cup, differential bearing, and selective outboard spacer(s) together. Note from which side they were removed (differential ring gear side or the opposite side).
2. NOTE: Use a vise with brass jaws or wood blocks.
Place the differential case in a vise.
3. CAUTION: Do not damage the anti-lock speed sensor ring when removing the differential ring gear. If removing the anti-lock speed sensor ring, discard it and install a new one.
NOTE: Always install new bolts upon assembly. Use Grade 9 bolts for all Dana rear axles.
Remove the bolts. Leave four bolts loosely assembled, 90 degrees apart.
4. Tap each bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove the bolts and the differential ring gear.
5. If necessary, remove the anti-lock speed sensor ring with a soft-faced hammer. Discard the anti-lock speed sensor ring.
6. The Truetrac and Trac-Lok differential assemblies are non-repairable. Discard the entire assembly if it is worn/damaged. For conventional differential assemblies, proceed as follows.
Conventional differential
7. NOTE: Use a vise with brass jaws or wood blocks.
Place the differential case in a vise.
8. Using a small drift, drive out the differential pinion shaft lock pin.
9. Using a drift, remove the differential pinion shaft.
10. To remove the differential side gears and the differential pinion gears, rotate the differential side gears. The differential pinion gears will turn to the opening in the differential case.
11. Remove the differential pinion gears and the differential pinion thrust washers behind the differential pinion gears.
12. Lift out the differential side gears and the differential side gear thrust washers.
Assembly
Conventional differential
1. NOTE: For Truetrac and Trac-Lok differential assemblies proceed to All differentials in this procedure.
NOTE: Use a vise with brass jaws or wood blocks.
Place the differential case in a vise.
2. Lubricate the new differential side gear thrust washers, the thrust face of the new differential side gears, the new differential pinion thrust washers, and the new differential pinion gears with grease.
3. NOTE: The best way to assemble the differential side gears and the differential pinion gears is to lubricate all parts with the specified rear axle lubricant.
Lubricate and assemble both differential side gears and differential side gear thrust washers. Hold them in place. Then, lubricate and assemble the differential pinion gears and the differential pinion gear thrust washers to hold the differential side gears in place.
4. NOTE: Rotate the differential side gears until the holes of the differential pinion gear thrust washers and the differential pinion gears line up with the holes of the differential case. If the differential pinion gears will not rotate by hand, install one of the axle shafts into the spline of the differential side gear and use a pipe wrench to turn the axle shaft.
Using a drift, line up the holes with those of the differential case.
5. Assemble the differential pinion shaft and drive on the differential pinion shaft to remove the drift. Align the lock pin hole in the differential pinion shaft with the lock pin hole in the differential case.
6. Assemble the differential pinion shaft lock pin. Peen the metal of the differential case over the differential pinion shaft lock pin in two places, 180 degrees apart, to lock it in place. Note the location of the slot in the differential pinion shaft lock pin and peen it 90 degrees apart.
All differentials
7. NOTE: Align the tab on the anti-lock speed sensor ring with the slot in the differential case.
NOTE: Apply Threadlock and Sealer to the new bolts.
Align the tab in the anti-lock speed sensor ring with the slot in the differential case. Start the two bolts through the differential case flange and into the differential ring gear to make sure the differential case and the differential ring gear bolt hole align.
8. Press the anti-lock speed sensor ring on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.
9. NOTE: Apply Threadlock and Sealer to the new bolt threads.
Draw up the Grade 9 bolts alternately and evenly.
10. Install the differential bearings.