Differential Overhaul (11.5 Inch Axle)

Differential Overhaul (11.5 Inch Axle)

Disassemble Procedure

1. Remove the differential case side bearings. Refer to Differential Bearing Replacement ().
2. Remove the differential ring gear from the differential case. Refer to Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) (Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle))Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) (Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle)).




3. Locate the end of the pinion shaft with the pilot hole.




4. Using a brass drift and a hammer, remove the pinion shaft from the differential case.




5. Remove and discard the retaining ring from the pinion shaft. Replace with NEW only.





Note: Mark the differential pinion gears top and bottom

6. Remove the differential pinion gears and the thrust washers by rolling the differential pinion gears out through the differential case opening.

Note: Mark the differential side gears left and right.

7. Remove the differential side gears and the thrust washers.

Assemble Procedure





Note: Ensure that the retaining ring is properly seated groove.

1. Install the NEW retaining ring on the differential pinion shaft.
2. Using the proper axle lubricant, lubricate the pinion and side gears. Refer to Fluid and Lubricant Recommendations (USA and Canada) (Maintenance).

Note: If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to their original locations.

3. Install the differential side gear thrust washers to the differential side gears.
4. Install the differential side gears and thrust washers in the differential case.





Note: If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to their original locations.

5. Install the thrust washers to the pinion gears.
6. Position one of the pinion gears with the thrust washer between the differential side gears.
7. Install the second pinion gear with the thrust washer between the differential side gears directly opposite of the first gear.
8. Rotate the differential side gears until the pinion gears and the thrust washers are directly opposite the opening in the differential case.





Note: When installing the differential pinion shaft, slide differential pinion until the retaining ring is against the differential case.

9. Using a brass drift and a hammer, install the differential pinion shaft.
10. Install the differential ring gear on the differential case. Refer to Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) (Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle))Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) (Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle)).
11. Install the differential side bearings. Refer to Differential Bearing Replacement ().