Rear

DISASSEMBLY





1. Using holding fixture J-42832 and holding fixture base J-3289-20, fix the differential assembly to the bench.
2. Remove bearing cap.





CAUTION: Bearing caps are machined with the carrier and must be assembled in the same position as removed. Note the matched letter (1) stamped on the caps and carrier. When assembled, the letters on the caps must agree in both the horizontal and vertical position with the letters on the carrier.

3. Remove differential cage assembly.
4. Remove side bearing outer race. After removal, keep the right and left hand side bearing assemblies separate to maintain inner and outer race combinations.





5. Remove side bearing by using remover J-42379 and adapter J-8107-3.Select collet halves 44803 in remover kit J-42379 for side bearing removal and insert is not required for this operation.
6. Note the thickness and position of the shims then remove adjust shim.





7. Remove the flange nut and washer by using pinion flange holder J-8614-01 after raising up its staked parts completely.
8. Removed flange assembly.





9. Remove the drive pinion assembly using a soft metal rod and a hammer.
10. Remove collapsible spacer.





11. Remove the inner bearing by using remover J-42379.Select insert 303174 and collet halves 44803 in remover kit J-42379 for inner bearing removal.
12. Remove adjust shim.
13. Remove oil seal.
14. Remove oil seal slinger.
15. Remove outer bearing.








16. Remove the inner bearing outer race (1) and the outer bearing outer race (2) by using a brass bar and a hammer.

REASSEMBLY





1. Install outer bearing outer race by using installer J-8611-01 and grip J-8092.





2. Install inner bearing outer race by using installer J-42831 and grip J-8092.
3. Adjust the drive pinion mounting distance as follows:
1. Apply gear oil to the inner and outer drive pinion bearing. Clean the pinion setting gauge set. Then install the gauge set together with the inner and outer bearings.





Install gauge plate J-42826 (3), inner pilot J-42827 (2) stud and nut J-21777-43 (4) and outer pilot J-42824 (1) through inner and outer bearings.
2. Tighten the nut to the specified torque.

Torque: 2.3 Nm (20 inch lbs.)





3. Clean the side bearing bores. Place discs and dial indicator on to arbor, and place tool into position in side bearing bores. Install and tighten the bearing caps to the specified torque.





4. Set the dial indicator J-8001 to "0". Place it on the mounting post of the gauging arbor with the contact button touching the indicator pad. Force the dial indicator downward until the needle has made a half turn clockwise. Tighten down the dial indicator in this position.





5. Position the plunger on the gauge plate. Move the gauging arbor slowly back and forth and locate the position at which the dial indicator shows the greatest defection. At this point, once again set the dial indicator to "0". Repeat the procedure to verify the "0" setting.





6. After the ZERO setting is obtained, rotate the gauging arbor until the dial indicator rod does not touch the gauging plate. Record the number the dial indicator needle points to.





7. Record the pinion depth code on the head of the drive pinion. The number indicates a necessary change in the pinion mounting distance. A plus number indicates the need for a greater mounting distance (which can be achieved by decreasing the shim thickness). A minus number indicates the need for a smaller mounting distance (which can be achieved by increasing the shim thickness). If examination reveals pinion depth code "0", the pinion is "nominal".





8. Select the shim thickness using the chart;





4. Place the shim (1) on the drive pinion, then install the inner bearing (2) onto the pinion by using installer J-42828 and a press.

NOTE: Do not apply pressure to the roller cage. Apply pressure only to the inner race.

5. Install collapsible spacer. Discard the used collapsible spacer and install a new one.
6. Install drive pinion shaft assembly.
7. Install outer bearing and oil seal slinger.





8. Use oil seal installer J-37263 to install a new oil seal that has grease on seal lip.
9. Install flange assembly.
10. Install flange nut and washer.
1. Apply lubricant to the pinion threads.
2. Using the pinion flange holder J-8614-01, tighten the nut only enough to remove the shaft end play.





NOTE: Discard used flange nut and install new one.

3. Adjust pinion bearing preload.
a. Measure the bearing preload by using a torque meter and note the scale reading required to rotate the flange.
b. Continue tightening flange nut until the specified starting torque is obtained.

Starting torque: 1.1 - 1.6 Nm (10 - 14 inch lbs.)





NOTE:
a. Do not overtighten or loosen and then retighten the nut.
b. Pinion nut torque should be in the range of 298 - 380 Nm (220 - 281 ft. lbs.).

4. Using punch J-39209, stake the flange nut at two points.





NOTE: When staking, be sure to turn the nut to ensure that there is no change in bearing preload. Make sure of preload again as instructed in 3).

11. Adjust ring gear backlash.





1. Attach the side bearing to the differential assembly without shims by using installer J-42829 and grip J-8092.





2. Insert the differential cage assembly with bearing outer races into the side bearing bores of the carrier.

3. Using two sets of feeler gauges, insert a feeler stock of sufficient thickness between each bearing outer race and the carrier to remove all end play. Make certain the feeler stock is pushed to the bottom of the bearing bores.





Mount the dial indicator J-8001 on the carrier so that the indicator stem is at right angles to a tooth on the ring gear.





4. Adjust feeler gauge thickness from side to side until ring gear backlash is in the specified range.

Backlash: 0.13 - 0.2 mm (0.005 - 0.008 inch)

With zero end play and correct backlash established, remove the feeler gauge packs, determine the thickness of the shims required and add 0.05 mm (0.002 inch) to each shim pack to provide side bearing preload. Always use new shims.





5. Remove side bearing by using remover J-42379 and adapter J-8107-3.





12. Install the side bearings together with the selected shims by using installer J-42829 (2) and grip J-8092 (1)
13. Install side bearing outer race.
14. Install differential cage assembly.





15. Install bearing cap.
Make sure the letter stamped on the caps corresponds with those on the carrier.





16. Tighten the bolt to the specified torque.

Torque:108 Nm (80 ft. lbs.)

GEAR TOOTH CONTACT PATTERN CHECK AND ADJUSTMENT








1. Apply a thin coat of Prussian blue or equivalent to the faces of the 7-8 teeth of the ring gear. Check the impression of contact on the ring gear teeth and make necessary adjustment as described in illustration if the contact is abnormal.





DIFFERENTIAL CAGE ASSEMBLY DISASSEMBLY
1. Remove bolt.
2. Remove ring gear.





3. Remove lock pin using a small drift.





4. Remove the differential shaft by using a hard metal rod and a hammer.
5. Remove pinion mate gear and thrust washer.
6. Remove side gear and thrust washer.

DIFFERENTIAL CAGE ASSEMBLY INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts:
- Ring gear, pinion gear
- Bearing
- Side gear, pinion mate gear, differential shaft
- Differential cage, carrier
- Thrust washer
- Oil seal

DIFFERENTIAL CAGE ASSEMBLY RING GEAR REPLACEMENT:
1. The ring gear should always be replaced with the drive pinion as a set.
2. Discard used bolts and install new ones.





3. Tighten the fixing bolts in a diagonal sequence as illustrated.

Torque: 177 Nm (130 ft. lbs.)

DIFFERENTIAL CAGE ASSEMBLY REASSEMBLY





1. Install side gear with thrust washer.





2. Install the pinion mate gear with thrust washer by engaging it with the side gears while turning both pinion mate gears simultaneously in the same direction.

3. Install differential shaft.





1. Be sure to install the differential shaft so that it is in alignment with the lock pin hole in the differential cage.

4. Install lock pin.
After lock pin installation, stake the case to secure the lock pin.
5. Install ring gear.





6. Tighten the bolts in diagonal sequence as illustrated.

Torque: 177 Nm (130 ft. lbs.)

NOTE: Discard used bolts and install new ones.





LOCKING DIFFERENTIAL ASSEMBLY DISASSEMBLY
1. Remove ring gear.
2. Place one of the axle shafts, which was removed from the assembly, into a vise. Tighten shaft in vise firmly. The spline end of the shaft is not to exceed 3 inches (76.2 mm) above the top of the vise. Position the differential on the shaft with the ring gear side down.
3. Remove Lock pin (1) from differential shaft using a punch.





4. Remove Differential shaft (2) using hammer and punch.
Place shop towel behind case to prevent differential shaft from dropping out of case.





5. Assemble clutch pack unloading tool.
a. Install cap J-34174-1 to the bottom differential side gear.
b. Install threaded screw cap J-34174-2 to top differential side gear. Thread forcing screws J-22342-15 into threaded screw cap until it becomes centered into the bottom cap.
c. Tighten forcing screw until tight enough to collapse dished spacers and allow looseness between side and pinion mate gears.





6. Both pinion mate gear thrust washers using a shim stock (1) of 0.51 mm (0.020 in.) or equivalent tool to push out washers.
7. Relieve tension of dished spacers by loosening forcing screw.

NOTE:
- You may have to adjust the forcing screw slightly to allow the case to rotate.

8. Insert differential shaft into its hole of case. Pull on shaft and rotate case until pinion mate gears can be removed.
9. Remove pinion mate gears.





10. Hold side gear top clutch pack (1) with one hand and remove positraction unloading tools.
11. Remove top side gear and clutch pack.

NOTE:
- Keep the stack of plates and discs intact and in exactly the same position while they are being removed.

12. Remove case from holder. Turn case with flange or ring gear side up to allow side gear and clutch pack to be removed from case.
13. Remove differential plate retainer from both clutch packs to allow separation of the plates and discs.





NOTE:
^ Keep the discs and plates in the same order as they were removed.

LOCKING DIFFERENTIAL ASSEMBLY INSPECTION AND REPAIR
Cleaning
- All parts with solvent.

Visual Inspection
- Clean all parts with solvent.
- Plates and Discs. If any one disc or plate in either stack shows evidence of excessive wear or scoring, the complete stack is to be replaced on both sides.
- Side Gears and Pinion Mate Gears. The gear teeth of these parts should be checked for extreme wear and possible cracks. The external teeth of the side gear, which retain the concentric groove discs, should also be checked for wear or cracks.
- If replacement of one gear is required due to wear, etc., then both side gears, pinion mate gears, and thrust washers are to be replaced.
- Differential Shaft. If excessive wear is evident, the differential shaft should be replaced.
- Differential Plate Retainers. If wear is evident on any one of the differential plate retainers, all four retainers must be replaced.
- Differential Case. If scoring, wear or metal pickup is evident on the machined surfaces, replacement of the case is necessary.

LOCKING DIFFERENTIAL ASSEMBLY REASSEMBLY
1. Lubricate thrust face of side gears, plates and discs with the proper limited slip rear axle lubricant.
2. Assemble plates and discs in exactly in the same position as they were removed, regardless of whether they are new or original.
3. Install differential plate retainer to ears of plates.

NOTE: Make sure both retainers are completely seated on ears of plates.

4. Install clutch pack and side gear into bottom side gear bore. Make sure clutch pack stays assembled to side gear splines, and that retainers are completely seated into pockets of case.

NOTE: To prevent clutch pack from falling out of case, hold clutch pack in place by hand while repositioning case on bench.

5. Install other side gear and clutch pack. Make sure clutch pack stays assembled to side gear splines, and retainers are completely seated into pockets of case.





6. Hold clutch pack in position and assemble screw cap J-34174-2, cap J-34174-1 and forcing screw J-22342-5. Tighten forcing screw into bottom cap to hold both clutch packs in position.
7. With tools assembled to case, position case on shaft by aligning splines of side gear with those of shaft. Tighten forcing screw to compress clutch packs in order to provide clearance for pinion mate gears.
8. Install pinion mate gears.
- Place the pinion mate gears into the differential 180 degrees apart.
9. While holding gears in place, insert differential shaft in its hole of case. Pull on shaft and rotate case, allowing gears to turn. Make sure that holes in pinion mate gears align with holes in case.
- It may be necessary to adjust tension on forcing screw to rotate case.
10. Tighten forcing screw to compress the clutch packs, to allow installation of tapered washers.





11. Lubricate tapered washers (2), and assemble into case (1). Use a small screw driver to push washers into place. Remove tools.





12. Position differential shaft in case and drive in with hammer. Be sure lock pin hole of differential shaft (5) is properly aligned to allow installation of lock pin (3). Be sure that thrust washers and differential pinion gears are aligned with the differential case (4). Install new lock pin to proper depth using a punch. Stake (peen) metal of case over pin in two places, 180 degrees apart.





13. Install ring gear and tighten the bolts in diagonal sequence as illustrated.

Torque: 177 Nm (130 ft. lbs.)

NOTE: Discard used bolts and install new ones.