Overhaul (Differential)

Component Location Index

Backlash Inspection





1. Install the driveshafts on the differential, then place the axles on V-blocks.
2. Check the backlash of the pinion gears (A) with a dial indicator (B).
Standard: 0.05 - 0.15 mm (0.002 - 0.006 inch)
3. If the backlash is out of standard, replace the differential assembly.

Differential Carrier/Final Driven Gear Replacement





1. Remove the final driven gear from the differential carrier. The final driven gear bolts have left-hand threads.
2. Install the final driven gear with the chamfered side on the inner bore facing the differential carrier in the direction shown.
3. Tighten the eight bolts in the position shown in a crisscross pattern.

Carrier Bearing Replacement

Special Tools Required
^ Driver 40 mm I.D. 07746-0030100
^ Attachment 35 mm I.D. 07746-0030400





1. Remove the bearings (A) with a commercially available bearing puller (B) and shaft protector (C).





2. Install the bearings with the special tools and a press. Press the bearing on until it bottoms.

Oil Seal Replacement

Special Tools Required
^ Driver 07749-0010000
^ Driver attachment, 58 mm 07JAD-PH80101
^ Driver attachment, 64 x 72 mm 07JAD-PN00100





1. Remove the oil seal from the transmission housing.





2. Remove the oil seal from the flywheel housing.





3. Install the new oil seal in the transmission housing with the special tools.





4. Install the new oil seal in the flywheel housing with the special tools.

Carrier Bearing Side Clearance Inspection

Special Tools Required
^ Driver 40 mm I.D.07746-0030100
^ Attachment 35 mm I.D. 07746-0030400





1. Install the differential assembly in the transmission housing, then drive the differential to seat it in the housing.





2. Install the three dowel pins (A) and the gasket (B) on the transmission housing (C).
3. Place the flywheel housing (D) on the transmission housing.
4. Install the housing bolts with the harness clamp bracket (E), and tighten the bolts in two or more steps in a crisscross pattern.





5. Install the set ring.





6. Measure the clearance between the set ring and carrier bearing outer race with a feeler gauge.
7. If the clearance is out of standard, remove the 66 mm set ring, and measure its thickness.





8. Select and install a new set ring, then recheck the clearance and make sure it is within the standard.