Part 1 of 2
Front Axle Differential Case
Material
1. Remove the differential case from the differential housing.
2. Remove the components in the order indicated in the illustration and table.
3. To assemble, reverse the disassembly procedure.
Rear Axle Assembly
Special Tool(s)
Material
1. Position the vehicle on a hoist.
2. Remove the rear axle assembly.
3. Remove the components in the order indicated in the illustration and table.
4. To assemble, reverse the disassembly procedure.
5. Fill the axle with the specified quantity of the specified lubricant.
Item 1: Pinion Nut Disassembly Note
1. Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions
2. CAUTION: After removing the nut, discard it. Use a new nut for installation.
Use the special tool to hold the rear axle pinion flange while removing the nut.
3. Index-mark the rear axle pinion flange to the drive pinion stem.
Item 2: Rear Axle Pinion Flange Disassembly Note
1. Using the special tool, remove the rear axle pinion flange.
Item 4: Rear Pinion Oil Seal Disassembly Note
1. Use a screwdriver to force up the metal flange of the rear pinion oil seal. Install gripping pliers and strike with a hammer to remove the rear pinion oil seal.
Item 15: Differential Case Disassembly Note
1. CAUTION: Do not damage the aluminum differential housing while carrying out these procedures.
Using the special tools, mount the differential housing to a work bench.
1 Attach the special tools to the differential housing with four bolts that retain the differential housing cover to the differential housing.
2 Attach the special tools together with two 3/8 inch x 1-1/2 inch bolts.
2. Install the special tool by placing the spreader pins in the hole in the Housing Spreader Adapters.
3. Assemble the special tools.
1 Install the special tool.
2 Attach the special tool and position the tip in the Housing Spreader Adapter hole.
4. CAUTION: Overspreading can damage the differential housing.
NOTE: Tighten and loosen the Differential Carrier Spreader screw to normalize the Housing Spreader Adapters prior to taking the final Dial Indicator reading.
Spread the differential housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the screw until the differential housing is spread to the specification.
3 Remove the special tool.
5. CAUTION: Mark the position and location of the differential bearing caps as the arrows may not be visible. Always install the differential bearing caps in their identical location and position.
Remove the differential bearing caps.
1 Remove the bolts.
2 Remove the differential bearing caps.
6. CAUTION: Use wood blocks to avoid damaging the differential housing.
Remove the differential assembly.
1 Position wood blocks at the top and bottom of the differential case.
2 Pry the differential assembly and the differential bearing shims out of the differential housing.
3 Mark the bearing cups and shims for location on installation.
^ Remove the special tool.
Item 18: Differential Bearing Disassembly Note
1. Using the special tools, remove the differential bearing.
^ Repeat for the other side.
Item 21: Differential Pinion Gear Disassembly Note
1. Using the special tool and a hammer, remove the differential pinion gear from the differential case.
Item 22: Inner Pinion Bearing Disassembly Note
1. Using the special tool and a press, remove the pinion bearing.
1 Position the special tool under the pinion bearing.
2 Using a press, remove the pinion bearing.
Item 30: Axle Isolator Bushing Disassembly Note
1. Using a hammer and the special tools, remove the rear axle isolator bushing.
Item 31 and 32: Inner and Outer Pinion Bearing Cup Disassembly Note
1. Using a brass drift and a hammer, remove any damaged differential drive pinion bearing cup from the differential housing. Tap alternately on each side of the cup to prevent it from cocking in the bore.
Item 32 and 31: Outer and Inner Pinion Bearing Cup Assembly Note
1. Coat the new differential drive pinion bearing cup(s) with lubricant.
2. Using the special tool, install the differential drive pinion bearing cup(s).
1 Position the bearing cup(s) on the special tool.
2 Position the special tool and the bearing cup(s) in the differential housing.
3 Tighten the special tool to fully seat the bearing cup(s) in the bore(s).
Item 30: Axle Isolator Bushing Assembly Note
1. Using the special tools, install the rear axle isolator bushing.
Item 23: Drive Pinion Bearing Adjustment Shim Assembly Note
1. NOTE: Apply a light film of lubricant on the front and rear pinion bearings.
Install the pinion bearings and special tools as shown.
2. NOTE: This step duplicates pinion bearing preload.
Thread the special tool onto the Screw and tighten to the specification shown.
3. CAUTION: Offset the special tool to obtain an accurate reading.
Rotate the special tool several half turns to seat the pinion bearings. Position the special tool as shown.
4. Install the special tool.
1 Position the special tool on the differential housing differential bearing seat.
2 Install the differential bearing caps.
3 Install the bolts.
5. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the drive pinion bearing adjustment shim thickness between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection.
6. Remove all of the special tools.
7. CAUTION: Use the same pinion bearings and drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly.
Position the drive pinion bearing adjustment shim and the pinion bearing on the drive pinion gear stem.
Item 22: Inner Pinion Bearing Assembly Note
1. Using the special tools and a suitable press, firmly seat the drive pinion bearing adjustment shim and pinion bearing on the drive pinion gear stem.