Differential: Service and Repair

DISASSEMBLE
1. Remove final drive ring gear bolts and final drive ring gear.
2. Remove differential bearing.
3. Use suitable gear and pulley puller to remove differential bearing.
4. Remove speedometer drive gear.
5. Use punch to drive out differential pinion shaft lock pin from differential case.
6. Remove differential pinion shaft.
7. Remove differential side gears, pinion gears, pinion thrust washers, and differential side gear washers.
8. Check mating surfaces of differential case, side gears, and differential pinion gears for damage or wear. Replace as required.

ASSEMBLE
1. Place differential side gear thrust washers on differential side gears.
2. Install differential side gears.
3. Attach differential pinion thrust washers on pinion gears.
4. Rotate differential pinion gears into differential case.
5. Install differential pinion shaft.
6. Place differential rotator tool No. T92P-77000-BH, or equivalent, and dial indicator on differential case.
7. Move differential side gear up and down to measure differential side gear deflection. Clearance should measure 0.004-0.008 inch.
8. If clearance is not within specifications, change thickness of differential side gear thrust washers.
9. Use punch to install differential pinion shaft lock pin until lock pin is flush with differential case.
10. Install speedometer drive gear onto differential case.
11. Use hydraulic press to install differential bearings.
12. Install final drive ring gear and bolts. Torque bolts in criss-cross pattern to 83-94 ft lbs.