Differential Bearings

Differential Bearings





























Removal

1. Remove the drain plug and drain the lubricant.

2. Remove the rear axle assembly.

3. Remove the 10 differential housing cover bolts and the cover.

4. Using the Transmission Holding Fixture, mount the differential housing to a work bench.

1. Attach the Differential Housing Spreader Plates and Dial Indicator Gauge with Holding Fixture to the differential housing with 4 differential housing cover bolts.

2. Attach the Transmission Holding Fixture and Differential Housing Spreader Plates together with two 3/8-inch x 1-1/2-inch bolts.





5. NOTICE: RH spreader set screw must not be adjusted further down than flush or the spreader rocks and damages the seal and the housing.

Install the Differential Carrier Spreader by placing the spreader pins in the hole in the housing spreader adapters.





6. Assemble the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.

1. Install the Dial Indicator Gauge with Holding Fixture.

2. Attach the Clutch Housing Gauge and position the tip in the housing spreader adapter hole.





7. NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters prior to taking the final Dial Indicator Gauge reading.

Spread the differential housing to the specification.

1. Adjust the Dial Indicator Gauge to zero.

2. Tighten the screw until the differential housing is spread to the specification.

3. Remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.





8. NOTE: Mark the position and location of the differential bearing caps. Always install the differential bearing caps in their original locations.

Remove the 2 differential bearing caps.

1. Remove the 4 differential bearing cap bolts.

2. Remove the 2 differential bearing caps.





9. NOTICE: Use wood blocks to avoid damaging the differential housing.

Remove the differential assembly.

1. Position wood blocks at the top and bottom of the differential assembly.

2. Pry the differential assembly and the differential bearing shims out of the differential housing.

3. Remove the Differential Carrier Spreader.





10. Using the Differential Bearing Remover and Step Plate, remove the 2 differential bearings.





11. If necessary, disassemble the differential assembly.

12. Using the Drive Pinion Flange Holding Fixture, hold the pinion flange to remove and discard the pinion nut.





13. Index-mark the pinion flange to the drive pinion stem.





14. Using the 2 Jaw Puller, remove the pinion flange.





15. Use a screwdriver to force up the metal flange of the drive pinion oil seal. Install gripping pliers and strike with a hammer to remove the drive pinion oil seal.





16. Remove the drive pinion oil seal deflector, drive pinion oil seal slinger, the outer pinion bearing and the drive pinion collapsible spacer.

17. Using the Drive Pinion Thread Protector and a soft-faced hammer, remove the differential pinion gear from the differential housing.





18. Using the Bearing Remover and a press, remove the drive pinion inner bearing.

1. Position the Bearing Remover under the drive pinion inner bearing.

2. Using a press, remove the inner drive pinion bearing and shim.





19. Using a brass drift and a hammer, remove the 2 differential drive pinion bearing cups from the differential housing. Tap alternately on each side of the cup to prevent them from cocking in the bore.





20. Inspect the differential case for wear or damage. If necessary, disassemble the differential case. For additional information, refer to Differential Case and Ring Gear Overhaul.

Installation

1. Using the Drive Pinion Bearing Cup Installers, install the 2 differential drive pinion bearing cups.

1. Position the bearing cups on the Drive Pinion Bearing Cup Installers.

2. Position the Drive Pinion Bearing Cup Installers and the 2 differential drive pinion bearing cups in the differential housing.

3. Tighten the Drive Pinion Bearing Cup Installers to fully seat the differential drive pinion bearing cups in the bores.





2. NOTE: If a feeler gauge of the specification shown can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.

Make sure the 2 differential pinion bearing cups are correctly seated.





3. NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.


Install the drive pinion bearings and Adapters as shown.












4. NOTE: This step duplicates drive pinion bearing preload.

Thread the Adapter onto the screw and tighten to the specification.

- Tighten to 2.2 Nm (20 lb-in) rotational torque.





5. NOTE: Offset the Adapter to obtain an accurate reading.

Rotate the Adapter several half turns to seat the drive pinion bearings. Position the Adapter as shown.





6. Install the Drive Pinion Gauge Tube.

1. Position the Drive Pinion Gauge Tube on the differential housing differential bearing seat.

2. Install the 2 differential bearing caps.

3. Install the 4 differential bearing cap bolts.
- Tighten to 111 Nm (82 lb-ft).





7. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the drive pinion bearing adjustment shim thickness between the gauge block and the gauge tube. A slight drag indicates correct shim selection.





8. Remove the Adapters and Drive Pinion Gauge Tube.

9. NOTE: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly.

Position the drive pinion bearing adjustment shim and the inner pinion bearing on the drive pinion gear stem.

10. Using the Bearing/Oil Seal Plate and Drive Pinion Bearing Cone Installer and a suitable press, firmly seat the selected drive pinion bearing adjustment shim and inner pinion bearing on the drive pinion gear stem.





11. Place a new differential drive pinion collapsible spacer on the drive pinion gear stem against the pinion stem shoulder.





12. Install the outer pinion bearing and the drive pinion oil seal slinger.





13. NOTE: If the drive pinion seal becomes misaligned during installation, remove it and install a new drive pinion seal.

NOTE: Coat the drive pinion seal lips with grease.

Using the Drive Pinion Oil Seal Installer, install the new drive pinion seal.





14. Install the drive pinion gear with the differential drive pinion collapsible spacer in the differential housing.





15. Position the pinion flange.

1. Lubricate the pinion flange splines with grease.

2. Align the pinion flange.





16. Using the Drive Pinion Flange Installer, install the pinion flange.





17. NOTICE: Do not, under any circumstance, loosen the pinion nut to reduce drive pinion bearing preload or damage to the component may occur. If it is necessary to reduce drive pinion bearing preload, install a new differential drive pinion collapsible spacer and pinion nut.

NOTE: Remove the Drive Pinion Flange Holding Fixture while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench.

Use the Drive Pinion Flange Holding Fixture to hold the pinion flange while tightening the pinion nut.

- Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (lb-in) torque wrench.





18. Tighten the pinion nut to set the drive pinion bearing preload. Refer to the torque specification for drive pinion bearings in the Specifications.





19. Press the left and right differential bearing on the differential assembly.

1. Position the differential bearings.

2. Using the Differential Side Bearing Installer, press the differential bearing on the differential assembly.





20. Install the differential assembly.





21. Install a differential bearing shim of the thickness shown on the LH side of the differential case.





22. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.

Install the left bearing cap and loosely install the 2 bearing cap bolts.





23. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.

Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.





24. Install the right bearing cap and 2 bolts.

25. Tighten the 4 differential bearing cap bolts.
- Tighten to 111 Nm (82 lb-ft).





26. Rotate the differential case to make sure it turns freely.





27. Install the Dial Indicator Gauge with Holding Fixture at the 12 o'clock position.





28. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the differential ring gear backlash at 4 equally spaced points.

1. Attach the Dial Indicator Gauge.

2. Position the Clutch Housing Gauge tip centrally on a drive tooth.

3. Zero the Dial Indicator Gauge.

4. Turn the differential ring gear without turning the drive pinion gear. Record the Dial Indicator Gauge reading. The allowable backlash is 0.203-0.305 mm (0.008-0.012 in) and must not vary more than 0.101 mm (0.004 in) between points measured. A backlash variation of more than 0.101 mm (0.004 in) between points checked indicates gear/case runout.
- To correct for a high or low backlash, proceed as follows.





29. To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the following tables when adjusting the backlash.









Differential Shim Size Chart - 4067







30. Remove the 4 differential bearing cap bolts.
- Remove the differential assembly.





31. Measure the thickness of the selected right and left bearing shims.

32. To establish differential bearing preload, increase both the left and right differential bearing shim thickness by 0.203 mm (0.008 in).

33. NOTICE: To avoid galling the case, insert shims with a light coating of grease before installing the differential assembly. If not carried out in this order, the aluminum housing can be damaged.

Place the 2 differential bearing shims in the differential housing.





34. Install the Differential Carrier Spreader, Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.





35. NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters prior to taking the final Dial Indicator Gauge reading.

Spread the differential housing to the specification.

1. Adjust the Dial Indicator Gauge to zero.

2. Tighten the screw until spreading the differential housing to the specification.

3. Remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.





36. Install the differential assembly.

1. Position the 2 differential bearing cups on the 2 differential bearings.

2. Lower the differential assembly in place between the 2 differential bearing shims.





37. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.

Install the 2 differential bearing caps and the 4 differential bearing cap bolts in their original locations and positions.





38. Loosen and remove the Differential Carrier Spreader.





39. Tighten the 4 differential bearing cap bolts.
- Tighten to 111 Nm (82 lb-ft).





40. Install the Dial Indicator Gauge with Holding Fixture at the 12 o'clock position.





41. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the ring gear backlash.





42. Apply marking compound and rotate the differential assembly 5 complete revolutions.





43. Verify an acceptable pattern check.

44. NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.

NOTE: Allow the sealant to cure for one hour before filling the axle with lubricant.

Apply a continuous bead of silicone gasket and sealant, of the specified thickness, to the differential housing cover mounting surface as shown.

- Use silicone gasket and sealant.





45. Install the differential housing cover and 10 housing cover bolts.

46. Install the rear axle assembly. For additional information, refer to Axle Assembly Axle Assembly.

47. Install the drain plug and remove the fill plug.
- Tighten to 34 Nm (25 lb-ft).

48. Fill the axle assembly with the specified lubricant.

49. Install the fill plug.
- Tighten to 34 Nm (25 lb-ft).