Overhaul

Differential Overhaul

^ Tools Required
^ J22912-01 Split Plate Bearing Puller
^ J 25299 Side Bearing Installer
^ J 8092 Driver Handle
^ J 8107-2 Side Bearing Puller Pilot (7.6 inch axle)
^ J 8107-4 Side Bearing Puller Pilot (8.6 inch axle)

Disassembly Procedure





1. Remove the differential side bearings by performing the following steps:
1.1. Install the J22912-01 (2) and the J8107-2 (7.6 inch axle) or the J 8107-4 (8.6 inch axle) (1) as shown.
1.2. Remove the differential side bearings using the J22912-01 and a hydraulic press.

Notice: Do not pry the ring gear from the case. This will damage the ring gear and the differential case.





2. Remove the ring gear bolts.
The ring gear bolts have left-handed threads.
3. Remove the ring gear from the differential case.
Drive the ring gear off with a brass drift if necessary.





4. Remove the differential pinion gears and the differential side gears by doing the following:
4.1. Remove the pinion shaft lock bolt.
4.2. Remove the pinion shaft.
4.3. Roll the differential pinion gear out of the case with the pinion thrust washers.
4.4. Remove the differential side gears and the side gear thrust washers.
Mark the pinion gears top and bottom and the differential side gears left and right.

Assembly Procedure





1. Lubricate the pinion and side gears with axle lubricant. Use the proper fluid.
2. Install the thrust washers to the differential side gears.
If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to the original locations.
3. Install the differential pinion gears by doing the following:
3.1. Position one pinion gear between the differential side gears.
3.2. Rotate the differential side gears until the pinion gear is directly opposite the opening in the differential case.
3.3. Place the other pinion gear between the differential side gears. Line up the hole in both the pinion gears.
4. Install the thrust washers. Rotate the pinion gears toward the opening in order to permit the sliding in of the thrust washers.
5. Install the pinion shaft.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install a new pinion shaft lock bolt.
7. ^ Tighten the new pinion shaft lock bolt to 36 Nm (27 ft. lbs.) (7.6 inch axle).
^ Tighten the new pinion shaft lock bolt to 36 Nm (27 ft. lbs.) (8.6 inch axle).

Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.





7. Install the ring gear to the differential case.
8. Install two threaded studs into the ring gear on opposite sides.
9. Place the ring gear on the case. Align the studs with the holes in the case.
10. Install the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.
^ Tighten the ring gear bolts in sequence to 140 Nm (103 ft. lbs.) (7.6 inch axle).
^ Tighten the ring gear bolts in sequence to 120 Nm (90 ft. lbs.) (8.6 inch axle).





11. Install the differential side bearings by doing the following:
^ In order to protect the differential case, install the J 8107-2 (7.6 inch axle) or the J 8107-4 (8.6 inch axle) in the case on the side opposite the bearing installation.
^ Install the J 25299 (2) and the J 8092 (1) onto the differential case bearing as shown.
^ Drive the bearing onto the case using the J25299 (2) and the J8092 (1).