Overhaul (Disassembly and Assembly)

Rear Axle Differential Case





Material

1. Remove the differential case from the differential housing.
2. Disassemble the components in the order indicated in the illustration and table.











3. To assemble, reverse the disassembly procedure.
4. To assemble, reverse the disassembly procedure.

Item 2: Differential Pinion Shaft Lock Bolt Assembly Note

1. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with sealer.

Install a new pinion shaft lock bolt.

Rear Axle Differential Case Traction-Lok-





Special Tool(s)





Material

1. Remove the differential case from the rear axle housing.
2. Remove the differential ring gear.





3. To assemble, reverse the disassembly procedure.





4. Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
^ If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary.

Item 3: Differential Clutch Spring Disassembly Note

WARNING: The differential clutch spring is under tension. Remove the spring carefully. Failure to follow these instructions may result in personal injury.





1. Remove the differential clutch spring

Item 6: Differential Pinion Side Gear Disassembly Note





1. Remove the differential gears.
1 Remove the two differential pinion gears and pinion thrust washers
2 Remove the two differential side gears with the clutch packs and the shims and tag them "left" and "right"

Item 7: Differential Clutch Pack Disassembly Note





1. CAUTION: Keep the differential clutch packs in order. Do not mix them. Always reassemble them in the same sequence.

CAUTION: Do not use acids or solvents when cleaning the differential clutch packs. Wipe the components only with a clean, lint-free cloth.

Remove the differential clutch packs and shims from the differential side gears.
^ Clean and inspect the differential clutch packs for wear and damage. Clean and inspect the remaining differential components for wear and damage. Install new parts as necessary.

Item 8: Differential Clutch Pack Selective Shim Assembly Note





1. CAUTION: Use 118 ml (4 oz.) of additive friction modifier in the axle.

Lubricate each steel clutch plate with additive friction modifier and soak all friction plates for no less than 15 minutes.





2. CAUTION: Do not mix the clutch plates, clutch discs or shims from one side with the other.

Assemble the differential clutch packs (without the shims) on their respective differential side gear.





3. Place the base portion of the special tool in a vise.





4. Install the differential clutch pack and differential side gear (without the shim) on the special tool.





5. Position the special tool hand-tight on top of the differential clutch pack.





6. Install the special tool over the disc and differential clutch pack.





7. Install the nut.
8. Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim.





Selective Shims





9. Remove the special tool from the differential clutch pack and differential side gear assembly.
10. Install the shim(s) on the differential clutch pack and differential side gear assembly.

Item 7: Differential Clutch Pack Assembly Note





1. Install the differential side gear assemblies in the differential case.

Item 3: Differential Clutch Spring Assembly Note





1. Using a soft-faced hammer, install the differential clutch spring.

Item 1: Differential Pinion Shaft Lock Bolt Assembly Note





1. Install the differential pinion shaft and install a new bolt.