Differential Case

Differential Case

















Removal

1. Remove the axle shafts. For additional information, refer to Axle Shaft Service and Repair.

2. NOTE: Inspect the removed lubricant for metallic particles which indicate wear or damage.

Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.

3. Rotate the differential assembly to check for roughness indicating bearing/gear damage.





4. NOTE: Mark the position of the bearing caps, as the arrows may not be visible. Always install the bearing caps in their original locations and positions.

Remove the 4 bolts and the 2 bearing caps.





5. NOTICE: Place a wood block between the pry bar and the differential housing to protect the machined surface or damage to the component may occur.

Using a pry bar and a wood block, remove the differential assembly from the differential housing.





6. Remove and discard the 10 ring gear bolts.





7. NOTICE: Do not damage the differential ring gear bolt hole threads.

Insert a punch in the bolt holes and drive off the differential ring gear.





8. Position the differential assembly, including the differential bearing cups and differential bearing shims, in the differential housing. Install the 2 bearing caps and the 4 bolts.
- Tighten to 114 Nm (84 lb-ft).

9. Position the Dial Indicator with Holding Fixture.

1. Rotate the differential case to verify that the differential bearings have seated correctly.

2. Position the Dial Indicator with Holding Fixture.





10. Measure and note the differential case runout.
- If the runout does not exceed the specification, install a new differential ring gear and pinion. For additional information, refer to Differential Ring And Pinion Differential Ring and Pinion.

- If the runout exceeds the specification, the concern is due to differential case/differential bearing damage. Install a new differential case. For additional information, refer to Differential Case and Ring Gear - Conventional Differential Case and Ring Gear - Conventional.

11. Remove the 4 bearing cap bolts, the 2 bearing caps and the differential assembly from the axle housing.

12. Using the 2-Jaw Puller and Step Plate, remove the 2 differential bearings.





13. Using the Differential Side Bearing Installer, install the 2 new differential bearings.

1. Position the bearing.

2. Using the Differential Side Bearing Installer, press the bearings on the differential case.





14. Position the differential assembly, including the differential bearing cups and differential bearing shims in the differential housing. Install the 2 bearing caps and the 4 bolts.
- Tighten to 114 Nm (84 lb-ft).





15. Position the Dial Indicator with Holding Fixture.

1. Rotate the differential case to verify that the differential bearings have seated correctly.

2. Position the Dial Indicator with Holding Fixture.





16. Measure the differential case runout.
- If the runout does not exceed the specification, use the new differential bearings for assembly.

- If the runout exceeds the specification, install a new differential case. For additional information, refer to Differential Case and Ring Gear - Conventional Differential Case and Ring Gear - Conventional.

17. Remove the 4 bearing cap bolts, the 2 bearing caps and the differential assembly from the axle housing.

Installation

Assembly

1. Position the differential ring gear and the differential case. Align the bolt holes by starting 2 bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.

2. NOTE: Apply stud and bearing mount to the new bolt threads.

Install the 10 new differential ring gear bolts.

- Tighten to 114 Nm (84 lb-ft).





3. With the pinion depth set and pinion installed, place the differential assembly in the differential housing.





4. Install a differential bearing shim on the left side.





5. NOTE: Always install the bearing caps in their original locations and positions.

NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats correctly.

Install the left bearing cap and loosely install the 2 bolts.





6. Install progressively larger differential bearing shims on the right side until the largest shim selected is installed by hand.





7. Install the right side bearing cap and tighten the 2 left side and 2 right side bolts.
- Tighten to 114 Nm (84 lb-ft).





8. Rotate the differential case to make sure it turns freely.





Measuring backlash

9. Using the Dial Indicator with Holding Fixture and Clutch Housing Gauge, measure and note the differential ring gear backlash.
- If backlash is within the specification, refer to Backlash within specification in this procedure.

- If a zero backlash condition occurs, refer to Zero backlash in this procedure.

- If backlash is not within the specification, refer to Backlash not within specification in this procedure.










Zero backlash

10. If a zero backlash condition occurs, add 0.51 mm (0.020 in) to the RH side and subtract 0.51 mm (0.020 in) from the LH side to allow backlash indication. Measure the backlash. For additional information, refer to Measuring backlash in this procedure.





Backlash not within specification

11. To increase or decrease backlash, remove the bearing caps and install a thicker shim and a thinner shim accordingly.
- If backlash is not within the specification, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount.





12. Rotate the differential assembly several times to verify that the differential bearings seated correctly.





13. Using the Dial Indicator with Holding Fixture and Clutch Housing Gauge, recheck the backlash.
- If backlash is within the specification, refer to Backlash within specification in this procedure. If backlash is not within the specification, repeat Backlash not within specification in this procedure.





Backlash within specification

14. Remove the 4 bolts and the 2 bearing caps.

15. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown.





16. Using the Differential Shim Installer, fully seat the differential bearing shims. Make sure the assembly rotates freely.





17. Install the 2 bearing caps and 4 bolts.
- Tighten to 114 Nm (84 lb-ft).





18. Using the Dial Indicator with Holding Fixture and Clutch Housing Gauge, recheck the backlash.





19. Install the axle shafts. For additional information, refer to Axle Shaft Service and Repair.