Front Differential
DIFFERENTIAL CARRIER OVERHAULDisassembly Procedure
- Tools Required
- J2619-01 Slide Hammer
- J8763-02 Holding Fixture C Clamp
- J8614-01 Pinion Flange Remover
- J21551 Output Shaft Bearing Remover
- J22888 Differential Side Bearing Remover
- J29307 Slide Hammer J33791 Bushing Remover
- J33792 Slide Bearing Adjuster Wrench
- J33837 Pinion Bearing Cup Remover and installer
- J34011 Pilot Bearing Installer
1. Remove the bolts, the shift cable housing, and the spring.
2. Remove the tube and the thrust washer.
3. Remove the spring and shift shaft with fork.
4. Remove the axle shaft.
5. Remove the carrier connector with retaining ring.
6. Remove the right seal and bearing using tools J29369-01 and J29307.
7. Remove the seal from the tube, prying with a screwdriver.
8. Remove the thrust washer.
9. Remove the sleeve and output shaft.
10. Remove the differential pilot bearing from the output shaft using J34011.
11. Remove the washer.
12. Remove the shaft. Pull the output shaft out of the case using.
13. Remove the bolts and cover.
14. Remove the left seal.
15. Remove the bolts.
16. Separate the carrier case. Insert a screwdriver into the slots provided and pry to separate the case.
17. Remove the differential case.
18. Remove the bolts and lock tabs from the side bearing adjuster sleeves.
19. Remove the bearing cups and sleeves from the case.
20. Turn the sleeves until the cups are pushed out of the case using J33792.
21. Remove the bearing from the sleeve using J21551.
22. Remove the pinion flange nut and washer using J8614-01. Mount the left carrier case half in J33837.
23. Remove the pinion flange and deflector using J33837 and J33837-3.
24. Remove the pinion with the spacer and the pinion bearing and shim.
25. Remove the spacer from the pinion.
26. Remove the bearing from the pinion with a press and J22912-01.
27. Remove the shim.
28. Remove the bearing and seal using J33837, J33837-3 and J33837-6.
28.1. Insert J33837-6 into the pinion bore.
28.2. Thread the forcing screw (J33837-3) into J33837-6.
28.3. In order to pull the parts from the case, turn the forcing screw.
29. Remove the inner bearing cup by pushing out using tools J33837, J33837-3 and J33837-6.
30. Remove the bolt and shaft from the differential case.
31. Remove the differential pinion gears and the thrust washers.
32. Remove the side gears and the thrust washers. Mark the side gears and case for reinstallation in their original location.
33. Remove the bolts.
34. Remove the ring gear. Drive the gear off with a brass drift and hammer, do not pry between the ring gear and the case.
35. Remove the side bearings using J22888.
36. Remove the case bushing using J33791.
DIFFERENTIAL ASSEMBLY INSTALLATION
Installation Procedure
- Tools Required
- J33788 Output Shaft Bearing Installer
- J23423-A Bearing Cup Installer
- J33792 Side Bearing Adjuster Wrench
1. Install the bearings into the sleeves using J33788.
2. Install the sleeves into the carrier case. Thread the sleeves in all the way.
3. Install the side bearing cups into the carrier case using J23423-A.
4. Install the differential assembly to the carrier case.
4.1 Place the differential case assembly into the carrier case half which contains the pinion gear.
4.2 Turn the left sleeve in toward the differential case using J33792 until backlash is felt between the ring and pinion gear.
5. Install the carrier case halves. Do not use sealer at this time.
6. If the carrier halves do not make complete contact, back out the right hand adjusting sleeve. Use J33792.
7. Install the four bolts.
Tighten the bolts to 50 Nm (37 ft. lbs.).
Notice: Refer to Fastener Notice in Service Precautions.
RING AND PINION GEAR INSPECTION
1. The ring and pinion gears are matched sets and must be replaced any time a replacement of either is necessary.
2. Inspect the pinion and the ring gear teeth for the following conditions:
- Cracking
- Chipping
- Scoring
- Excessive wear
3. Inspect the pinion gear splines for wear.
4. Inspect the pinion flange splines for wear.
5. Inspect the fit of the pinion flange on the pinion gear.
6. Inspect the sealing surface of the pinion flange for nicks, burrs, or rough tool marks which will damage the inside diameter of the pinion seal and result in an oil leak.
7. Inspect all of the parts for wear and replace as necessary.
BEARINGS INSPECTION
Important:
^ When replacing the worn or cracked bearings and the cups, replace the bearings in sets.
^ The low mileage bearings may have very small scratches and pits on the rollers and the bearing cups from the initial preload. Do not replace a bearing for this reason.
1. Inspect the bearings for smooth rotation after oiling.
2. Inspect the bearing rollers for wear.
3. Inspect the bearing cups for the following conditions:
- Wear
- Cracks
- Brandling
- Scoring
THRUST WASHERS, SHIMS, AND ADJUSTER SLEEVES
- Inspect the shims and thrust washers for cracks and chips. Replace the damaged shims with an equally sized service shim.
- Inspect the adjuster sleeves for damaged threads. Replace the sleeves if required.
PINION BEARING CUP INSTALLATION
Installation Procedure
- Tools Required
- J33837 Pinion Bearing Cup Remover and Installer
1. Install the outer bearing into the case using J33837, J33837-3, and J33837-4.
2. Install the inner bearing into the case using J33837, J33837-3, and J33837-4.
PINION DEPTH ADJUSTMENT PROCEDURE
- Tools Required
- J33838 Pinion Shim Setting Gauge
- J29763 Dial Indicator
1. Adjust pinion depth by selecting a shim of the proper thickness.
2. Lubricate the inner and outer pinion bearings liberally with axle lubricant.
3. Hold the pinion bearings in position and install J33838.
4. Install the J29763.
4.1 Set the dial indicator at ZERO.
4.2 Position the indicator in J33838.
4.3 Push the dial indicator downward until the needle rotates approximately 3/4 turns to the right.
5. Tighten the dial indicator in this position.
6. Set the button of J33838 on the differential bearing bore.
7. Rotate the tool slowly back and forth until the dial indicator reads the lowest point of the bore. Set the dial indicator to ZERO. Repeat the rocking action of the tool in order to verify the ZERO setting.
8. After you obtain and verify the ZERO setting, move the tool button out of the differential side bearing bore. Record the dial indicator reading.
9. The dial indicator reading equals the shim size. For example, if the dial indicator reads 0.84 mm (0.003 inch) in step 8, a 0.84 mm (0.003 inch) shim is required.
10. Remove the tools and bearing cones.
DIFFERENTIAL CASE ASSEMBLE
Installation Procedure
- Tools Required
- J33790 Differential Side Bearing Installer
1. Install the thrust washers and side gears into the differential case. If reusing the original gears and washers, install the gears on the same side from which the parts were removed.
2. Install the pinion gears.
2.1 Position one pinion gear between the side gears. Rotate the gears until the pinion gear is directly opposite the opening in the case.
2.2 Place the other gear between the side gears. The hole in both pinion gears must line up.
3. Install the thrust washers. Rotate the pinion gears toward the opening in order to permit the thrust washers to slide in.
4. Install the shaft and the bolt.
5. Install the ring gear onto the differential case. Important: Always install new bolts. Do not reuse the old bolts.
Notice: Refer to Fastener Notice in Service Precautions.
6. Install the differential case bolts.
Tighten the bolts, in progressive steps, to 80 Nm (59 ft. lbs.).
7. Install the side bearings using J33792.
BACKLASH INSPECTION AND ADJUSTMENT
Adjustment Procedure
- Tools Required
- J33792 Side Bearing Adjuster Wrench
- J8001 Dial Indicator Set
- J25025-1 Dial Indicator Stand
Notice: Refer to Fastener Notice in Service Precautions.
- Tighten the right sleeve, then tighten the left sleeve to 140 Nm (103 ft. lbs.) using J33792.
1. Mark the location of the adjusting sleeves in relation to the carrier halves (1), in order to count the notches in the adjusting sleeves when turned.
2. Turn the right adjusting sleeve out two notches using J33792.
3. Turn the left adjusting sleeve in one notch using J33792.
4. Rotate the pinion several times in order to seat the bearings.
5. Install J34047, J25025-1, and J8001 (AWD only).
6. Place the indicator stem at the heel end of a tooth (AWD only).
7. Install a dial indicator so the button contacts the outer edge of the pinion flange. The plunger must be at a right angle to the pinion flange.
8. Move the pinion flange through the flange's free play while holding the differential carrier. Record the dial indicator reading.
9. Divide the dial indicator reading by two in order to obtain the actual backlash. For example, a dial indicator reading of 0.16 mm (0.006 inch) means that there is actually 0.08 mm (0.003 inch) backlash.
10. Check and record the backlash at three or four points around the ring gear.
- Hold the pinion stationary when checking backlash.
- If the backlash varies more than 0.05 mm (0.002 inch), check for the following conditions:
- Burrs
- A distorted case flange
- Uneven bolting conditions
- Foreign matter between the case and the ring gear
- Gear backlash should be between 0.08 - 0.25 mm (0.003 - 0.010 inch) with a preferred specification of 0.013 - 0.018 mm (0.005 - 0.007 inch).
- If the backlash is incorrect, adjust the sleeves as necessary. Maintain one notch preload on the side bearings. For example, if it is necessary to turn the right sleeve in one notch, turn out the left sleeve one notch.
- In order to increase backlash, turn the left sleeve in and turn the right sleeve out the same amount. In order to decrease backlash, turn the right sleeve in and turn the left sleeve out the same amount.
11. When the backlash is correct, mark the position of the sleeves in order to keep the sleeves in the same location.
DIFFERENTIAL CARRIER FINAL ASSEMBLY
Removal Procedure
1. Remove the 4 case bolts.
2. Remove the right carrier case half.
3. Clean the sealing surfaces on the carrier case halves. Remove all oil and grease using a chlorinated solvent, such as carburetor cleaner.
Installation Procedure
- Tools Required
- J33844 Axle Tube Bearing Installer
- J33893 Axle Shaft Seal Installer
- J22388 Pinion Oil Seal Installer
- J33842 Pilot Bearing Installer
- J33791 Bushing Remover and Installer
1. Apply a bead of sealer or equivalent to one carrier case surface.
2. Install the right carrier case.
3. Install the bolts.
Tighten the bolts to 47 Nm (35 ft. lbs. ).
Notice: Refer to Fastener Notice in Service Precautions.
4. Ensure that the sleeves are positioned properly, as previously marked.
5. Install the bolts and locks.
Tighten the bolts to 8 Nm (71 inch lbs.).
6. Fully support the seal bore area of the left seal to cover while installing.
7. Clean all oil and grease from the cover, bolts and carrier sealing surfaces using carburetor cleaner or equivalent.
8. Apply sealer or equivalent to the cover.
Tighten the bolts to 25 Nm (18 ft. lbs.).
9. Install and tap into place the shaft.
10. Install the bearing using tool J33844.
11. Install the shaft seal using J33893.
12. Install the shift housing seal using J33796.
13. Install the differential pilot bearing using J33842.
14. The washer to output shaft.
15. The output shaft to carrier assembly.
16. The sleeve.
17. The thrust washer using grease to secure.
18. The spring with shift shaft and fork.
19. Install the thrust washer using grease to secure, align the notch and tab.
20. The shaft to the tube.
21. The carrier connector with retaining ring, tap into place.
21.1. Remove all oil and grease from the tube and carrier gasket surfaces using carburetor cleaner or equivalent.
21.2. Apply sealer or equivalent to the carrier.
22. Install the tube assembly to the carrier.
23. Install the two upper bolts, leave finger tight.
24. Install the shift cable housing and remaining bolts.
Tighten the bolts to 47 Nm (35 ft. lbs.).
25. Install the bushings using tool J33791.
INSPECTION PROCEDURE
- Tools Required
- J33798 Hub Engagement Tool
1. Inspect the operation of the shift mechanism. Insert J33798 into the shift fork.
2. Turn the axle shaft while engaging and disengaging the shift mechanism with the tool.
3. The mechanism should operate smoothly. If not, remove the tube. Check for damaged or improperly installed parts.