Differential Carrier

Differential Carrier

Special Tool(s):

Material:

Removal
1. Remove the axle assembly.
2. Remove the differential housing cover.
^ Drain the fluid.
^ Remove the 10 differential housing cover bolts.
^ Remove the differential housing cover.

3. Using the special tools, remove the intermediate shaft.

4. Remove the axle housing tube.

5. CAUTION: The fixture mounting bolts must have the minimum specified thread engagement in the carrier.

Install the special tool.

6. CAUTION: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier.

Install the special tools.

7. Position the special tool on the spreader adapters.

8. Install the special tools.
^ Position the adapter tip in the spreader adapter hole.

9. CAUTION: Overspreading can damage the axle housing.

Spread the axle housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the housing spreader screw to spread the axle housing to the specification.
3 Remove the special tool.

10. CAUTION: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the differential bearing caps in their original positions.

Mark and remove the differential bearing caps.
1 Remove the 4 differential bearing cap bolts.
2 Remove the differential bearing caps.

11. CAUTION: Use wood blocks to avoid axle housing damage.

CAUTION: Index-mark the position of the differential bearing shims. The differential bearing shims must be installed in their original locations and positions.

Remove the differential carrier from the axle housing.
1 Position the wood blocks.
2 Position and push down on the 2 pry bars.
3 Remove the differential carrier.
4 Remove the special tool.

Installation

1. NOTE: Make sure the indicator needle is in the spreader adapter hole.

Install the special tools.

2. CAUTION: Overspreading can damage the axle housing.

Spread the axle housing to the specification.
^ Remove the dial indicator.

3. CAUTION: Never attempt to drive the differential bearing shim in place. Permanent damage to the machined axle housing surfaces can occur.

Position the differential bearing shims.
1 Apply a light coating of grease to one side of the differential bearing shims to help hold them in place.
2 Position the differential bearing shims.

4. NOTE: Push the differential carrier downward to fully seat the differential bearing cups in the axle housing.

Position the differential carrier.
1 Position the differential bearing cups on the differential bearings.
2 Lower the differential assembly in place between the differential bearing shims.

5. Install the differential bearing caps in their original positions and tighten with the housing still spread.
1 Position the differential bearing caps.
2 Install the 4 differential bearing cap bolts.
Tighten to 105 Nm (77 lb-ft).
3 Remove the special tool.

6. Install the special tool.

7. Using the special tools, measure the differential ring gear backlash at 4 equally spaced points.
1 Attach the special tool.
2 Position the special tool tip centrally on a drive tooth.
3 Zero the indicator.
4 Turn the differential ring gear without turning the drive pinion gear.

8. Install a new O-ring and new circlips on the intermediate shaft ends.

9. Install the axle housing tube.
^ Tighten to 73 Nm (54 lb-ft).

10. Install a new stub shaft seal.
11. Insert the intermediate shaft and engage the circlip with the differential side gear.
12. Remove the axle assembly from the special tool and place it on the bench.

13. CAUTION: Remove all of the silicone gasket and make sure the machined surfaces are free of oil before applying the new silicone gasket.

CAUTION: Install the differential housing cover within 15 minutes of applying the silicone gasket, or it will be necessary to remove and reapply silicone gasket. If possible, allow 1 hour before filling with lubricant to make sure the silicone gasket has cured.

Fill the sealing groove on the differential housing cover with silicone gasket.

14. Install the differential housing cover and the 10 differential housing cover bolts.
^ Tighten to 32 Nm (24 lb-ft).

15. Fill the axle housing with axle lubricant and install the fill plug.
^ Tighten to 25 Nm (18 lb-ft).

16. Install the axle assembly.