Differential Replacement

Differential Replacement

^ Tools Required
- J 80011 Dial Indicator Set
- J 45222 Axle Housing Spreader
- J 45222-10 Axle Housing Spreader Adapters
- J 3289-20 Holding Fixture
- J 34178 Spreader Gage Adapter
- J 45935 Holding Fixture

Removal Procedure





1. Remove the differential carrier assembly from the vehicle.





2. Remove the bolts retaining the front axle shaft housing tube to the front drive axle housing.
3. Remove the front axle shaft housing tube assembly.





4. Install the J-45935 (1) to the front drive axle housing using axle mounting bolts.
5. Insert the J-45935 (1) into the bench mounting fixture J 3289-20 (2).
6. Install the locking pin J 3289-22 (3), then tighten the set screw (4).





7. Remove the front axle housing cover bolts.
8. Remove the front axle housing cover and gasket.





9. Install the J-45222-10 (1) to the front axle housing as shown.
10. Install the J 45222 (2) to the J-45222-10 as shown.





11. Install the J 8001-1 (2), the J 8001-2 (3), the J 34178 (4, 6), and the J 8001-3 (5) as shown.
12. Preload the J 8001-3 approximately 3/4 of a turn clockwise.
13. Rotate the indicator housing to align the indicator needle of the J 8001-3 (5) and the dial indicator face to ZERO.
14. Spread the axle housing by turning the clevis screw of the J 34178 while observing the J 8001-3. Spread the housing just enough to remove the differential assembly. DO NOT spread the housing more than 1.02 mm (0.040 inch).





15. Mark the bearing caps left and right then remove the bearing cap bolts and the bearing caps.





Caution: To prevent personal injury and(or component damage, support the differential case when removing the case from the axle housing. If the case is not supported; the differential case could fall and cause personal injury or damage to the differential case.

Notice: When removing the differential case from the a)de housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.

16. Remove the differential case from the axle housing using a pry bar and a block of wood.
17. Remove the bearing cups, the shims, and the spacers as necessary. Mark the cups and shims left and right and in order as necessary. Place the cups and the shims with the bearing caps.
18. Remove the J 8001 - 1, the J 8001-2, the J 34178 and the J 8001-3.
19. Remove the J 45222 and the J-45222- 10.

Installation Procedure





1. Lubricate the differential side bearings with axle lubricant. Use the proper fluid.
2. Install the J-45222-10 (1) and the J 45222 (2) to the front axle housing as shown.





3. Install the J 8001-1 (2), the J 8001-2 (3) the J 34178 (4, 6), and the J 8001-3 (5) as shown.
4. Preload the J 8001-3 (5) approximately 3/4 of a turn clockwise.
5. Rotate the indicator housing to align the indicator needle of the J 8001-3 (5) and the dial indicator face to ZERO.
6. Spread the axle housing by turning the clevis screw of the J 34178 while observing the J 8001-3. Spread the housing just enough to remove the differential assembly. DO NOT spread the housing more than 1.02 mm (0.040 inch).





7. Place the case with the bearing cups installed into the axle housing.
8. Install the bearing caps and bolts. Do not torque the bearing cap bolts at this time.
9. Adjust the differential side bearing preload.
10. Adjust the backlash.
11. Perform the gear tooth contact pattern check.

Notice: Refer to Fastener Notice in Service Precautions.

12. Tighten the bearing cap bolts.
^ Tighten the bearing cap bolts to 63 Nm (46 ft. lbs.).
13. Install the front axle housing cover gasket.
14. Install the front axle housing cover and bolts.
^ Tighten the bolts to 30 Nm (22 ft. lbs.).
15. Install the front axle shaft housing tube assembly to the front drive axle housing.
16. Install the bolts retaining the front axle shaft housing tube assembly to the front drive axle housing.
^ Tighten the front axle shaft tube to axle bolts to 60 Nm (44 ft. lbs.).
17. Remove the J-45935 from the front drive axle housing.
18. Install the differential carrier assembly to the vehicle.