Differential Case and Ring Gear - Conventional

Differential Case and Ring Gear - Conventional










Disassembly

1. Remove the differential carrier. For additional information, refer to Differential Carrier Differential Carrier.

2. Using the Differential Carrier Bearing Step Plate, Differential Carrier Bearing Collets, Differential Carrier Bearing Retaining Ring, Bearing Tube Remover/Installers, Bearing Tube Removal Screw, remove and discard the differential bearings.
- Place the left and right differential bearing shims with the respective outboard spacers.





3. NOTE: Whenever removing the differential ring gear bolts, always install new Grade 9 differential ring gear bolts.

Remove and discard 8 of the differential ring gear bolts. Leave 4 differential ring gear bolts loosely assembled, 90 degrees apart.





4. Tap each differential ring gear bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove and discard the 4 differential ring gear bolts. Remove the differential ring gear.





5. NOTE: Use a vise with brass jaws or wood blocks.

Place the differential case in a vise.

6. Using a suitable tool, drive out the differential pinion shaft lockpin.





7. Using a suitable tool, remove the differential pinion shaft.





8. 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.





9. Remove the differential pinion gears and the differential pinion thrust washers.

10. Lift out the differential side gears and the differential side gear thrust washers.

Assembly

1. NOTE: Use a vise with brass jaws or wood blocks.

Place the differential case in a vise.

2. 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 with the differential pinion gear thrust washers to hold the differential side gears in place.





3. 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 suitable tool, line up the holes with those of the differential case.

4. Position the differential pinion shaft. Align the lockpin hole in the differential pinion shaft with the lockpin hole in the differential case.

5. Assemble the differential pinion shaft lockpin. Peen the metal of the differential case over the differential pinion shaft lockpin in 2 places, 180 degrees apart, to lock it in place. Note the location of the slot in the differential pinion shaft lockpin and peen it 90 degrees apart.





6. NOTE: If removed, install the anti-lock speed sensor ring.

Start 2 new ring gear bolts through the differential case flange, the anti-lock sensor ring and into the differential ring gear to make sure the differential ring gear and the differential case align.





7. Press the differential ring gear on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.





8. Install the 10 remaining ring gear bolts alternately and evenly.
- Tighten the new bolts to 298 Nm (220 lb-ft).





9. Using the Differential Carrier Bearing Installer, install the differential bearing and shim on the LH side of the differential case.





10. Using the Differential Carrier Bearing Step Plate and Differential Carrier Bearing Installer, install the differential bearing.

1. Place the Differential Carrier Bearing Step Plate on the differential bearing to protect it during the installation of the opposite bearing.

2. Using the Differential Carrier Bearing Installer, drive the differential bearing onto the hub.





11. Assemble the new differential bearing cups to the new differential bearings.

12. Install the differential carrier. For additional information, refer to Differential Carrier Differential Carrier.