Split Case Type
Fig. 1 Marking bearing caps:
DISASSEMBLY
1. Apply identification punch marks on the carrier, differential bearing cap and adjuster for reassembly purposes, Fig. 1.
2. Remove the adjuster lock plate.
3. Loosen the bearing cap attaching bolts and back off the adjuster slightly with wrench (49 0259 720) to relieve differential bearing preload.
Fig. 17 Split case differential assembly:
4. Remove the bearing caps and adjusters, Fig. 17.
5. Remove the differential assembly together with the bearing outer races. Make certain that each bearing outer race remains with its respective bearing.
6. If bearing replacement is necessary, remove the bearings from the differential gear case with a suitable puller.
7. Separate the differential case halves by removing the bolts.
8. Remove the side gears, thrust washers, pinion gears and spider.
9. Remove the bolts and washers that attach the ring gear to the gear case. Remove the ring gear.
10. Hold the companion flange with the holder (49 0259 710A) and remove the drive pinion nut.
11. Remove the companion flange.
12. Remove the drive pinion, rear bearing and collapsible spacer from the carrier. If necessary, tap the pinion out with a plastic hammer, while being careful to guide the pinion by hand to avoid damage.
13. Remove the oil seal and front bearing from the carrier.
14. Disassemble and inspect all parts, Fig. 17. If damaged replace as necessary.
15. Measure the length of the collapsible spacer with a micrometer. The standard length is 59 ± 0.15 mm (2.3299 ± 0.0059 in).
DRIVE PINION, ADJUST
The drive pinion should be correctly positioned in relation to the ring gear by the use of spacer which is placed between the drive pinion and the pinion rear bearing.
Fig. 4 Zeroing dial indicator:
1. Install the dial indicator to the gauge body. Place the gauge body on the surface plate, Fig. 4. Lock the dial indicator in position so that the needle is pointing toward 1 to 3 mm. Then, set the reading to ``Zero'' by turning the outer ring of the indicator.
2. Make certain that the differential bearing support bores are free of dirt and burrs.
Fig. 18 Installing drive pinion with adjusting gauge. Split case differential:
3. Install the pinion and bearing model (49 1029 572) together with a spacer into the carrier, Fig. 18.
Fig. 19 Measuring drive pinion adjustment:
4. Place the gauge block on the pinion and carefully place the gauge body adjusted in Step 1 on the gauge block so that the feeler of the indicator comes in contact with the lowest portion of the differential bearing support bore, Fig. 19.
5. Record dial indicator reading:
a. If the dial indicator shows ``+'' (plus), add the amount equivalent to the reading.
b. If the dial indicator shows ``-'' (minus), subtract the amount equivalent to the reading.
6. Remove the gauge body and dial indicator from the carrier and check zero setting on the surface plate to make sure this setting was not disturbed.
Fig. 20 Drive pinion markings:
7. In order to compensate for all of the machining variables, the pinion has a plus or minus reading recorded in hundredth millimeters on the rear face of the pinion, Fig. 20.
Example:
M + 2 = +0.02 mm
M - 1 = 0.01 mm
a. If the pinion is marked ``+'' (plus), subtract the amount specified on the pinion.
b. If the pinion is marked ``-'' (minus), add the amount specified on the pinion.
Fig. 21 Measuring rear pinion bearing height:
Fig. 22 Pinion spacer chart. Split case differential:
8. Place the bearing model and the rear pinion bearing on the surface plate and compare their heights, Fig. 21.
a. If the bearing is higher than the model subtract the amount equivalent to the difference.
b. If the bearing is lower than the model, add the amount equivalent to the difference.
9. Select the correct pinion spacer to be used during pinion assembly by adding or subtracting the amount determined in Steps 5, 7 and 8 from the thickness of the spacer used in Step 3. The spacers are available in eight thicknesses shown in Fig. 22.
10. Position the correct spacer on the pinion and install the rear pinion bearing.
PINION BEARING PRELOAD, ADJUST
1. Install the collapsible spacer onto the drive pinion and install them in the carrier.
2. Place the front pinion bearing in position on the pinion. Hold the pinion fully forward and drive the pinion bearing over the pinion until seated.
3. Apply gear lubricant to the lip of the pinion oil seal and install the pinion oil seal into the carrier.
4. Install the companion flange on the pinion by tapping with a plastic hammer.
5. Install the pinion washer and nut. Before tightening the nut (when the pinion preload is zero), determine the oil seal drag by using a torque wrench.
6. Tighten the pinion nut to 14 m-kg (101 ft.lbs.) and check the preload. After preload has been checked, final tightening should be done very cautiously.
7. The pinion nut should be further tightened only a little at a time and preload should be checked after each slight amount of tightening. Exceeding preload specifications will compress the collapsible spacer too far, necessitating its replacement. The maximum tightening torque of the nut is 20 m-kg (145 ft.lbs.). If the specified preload is not obtained after tightening the nut to the maximum torque of 20 m-kg (145 ft.lbs.), replace the collapsible spacer.
8. While observing the proceeding caution, carefully set the preload drag at 9 to 14 cm-kg (7.8 to 12.2 in. lb.) plus the oil seal drag determined in Step 5. If the preload is measured by using a spring scale at the bolt hole of the companion flange, the preload range drag is 2.1-3.3 kg (4.6-7.3 lb.), Fig. 6.
ASSEMBLY
Fig. 7 Installing thrust washer on side gears:
1. Install the thrust washer on each differential side gears and install these in the gear case, Fig. 7.
2. Fit the pinion gears onto the spider and install the spider into the differential case.
Fig. 23 Split case differential identification marks:
3. Align the identification marks, Fig. 23, secure the case halves together with bolts. Torque the bolts to 2.5 to 3.0 m-kg (18 to 21 ft.lbs..).
Fig. 7 Installing thrust washer on side gears:
4. Check the backlash of the side gear and the pinion gear. The backlash should be 0 to 0.1 mm (0 to 0.004 in.). If it is more than 0.1 mm (0.004 in.), adjustment can be made with the side gear thrust washers, Fig. 7. The following thrust washers are available:
Identification Mark Thickness
9 1.9 mm (0.0751 in.)
0 2.0 mm (0.0787 in.)
1 2.1 mm (0.0827 in.)
2 2.2 mm (0.0866 in.)
3 2.3 mm (0.0905 in.)
5. Install the ring gear to the case and torque the bolts to 9.0-11.0 m-kg (65-80 ft.lbs.).
6. Install each differential bearing to the gear case.
7. Install the differential bearing outer races to their respective bearings.
8. Place the differential gear assembly in the carrier, ensuring marks on the face of the pinion and ring gear tooth are in alignment.
Fig. 13 Installing bearing adjusters:
9. Note the identification marks on the adjusters and install each to its respective side, Fig. 13.
10. Install the differential bearing caps ensuring identification marks on the caps correspond with those on the carrier then install the attaching bolts.
11. Turn the adjusters with wrench (49 0259 720) until the bearings are properly positioned in their respective outer races and the endplay is eliminated with some backlash existing between the ring gear and drive pinion.
12. Slightly tighten one of the bearing cap bolts on each side and adjust the backlash.
Backlash, Adjust
1. Secure a dial indicator to the carrier flange so that the feeler comes in contact at right angles with one of the ring gear teeth.
Fig. 14 Measuring ring & pinion backlash:
2. Check the backlash between the ring gear and drive pinion. With the wrench (49 0259 720), Fig. 14, turn both bearing adjusters equally until the backlash becomes 0.17 to 0.19 mm (0.0067 to 0.0075 in.).
Fig. 15 Measuring distance between bearing caps:
3. The preload on the differential bearings is obtained by tightening the adjusters. Tighten the adjusters until the distance between both pilot sections on the bearing caps becomes 185.428 to 185.5 mm (7.3004 to 7.3033 in.), Fig. 15. When adjusting the preload, care must be taken not to affect the backlash of the drive pinion and ring gear.
4. Tighten the bearing cap bolts to a torque of 3.2 to 4.7 m-kg (23 to 34 ft.lbs.).
5. Install the adjuster lock plates on the bearing caps to prevent the adjusters from loosening.
Fig. 16 Correct pinion to ring gear contact:
6. Check the tooth contact of the ring gear and pinion by applying a thin coat of red lead on both sides of about six to eight of ring gear teeth and rotating the ring gear few times in both directions. If the pinion position and backlash have been correctly set, the contact pattern should be as shown in Fig. 16.