Differential Bearings
Differential BearingsSpecial Tools (part 1):
Special Tools (part 2):
Special Tools (part 3):
Special Tools (part 4):
Special Tool(s)
Material:
Material
Removal
1. Remove the rear axle assembly.
2. Remove the differential housing cover and drain the lubricant.
3. 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 4 differential housing cover bolts.
2 Attach the special tools together with 2 3/8-inch x 1 1/2-inch bolts.
4. CAUTION: RH spreader set screw must not be adjusted further down than flush or the spreader rocks and damages the seal and the housing.
Install the special tool by placing the spreader pins in the hole in the housing spreader adapters.
5. Assemble the special tools.
1 Install the special tool.
2 Attach the special tool and position the tip in the housing spreader adapter hole.
6. 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.
7. 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 locations and positions.
Remove the differential bearing caps.
1 Remove the differential bearing cap bolts.
2 Remove the differential bearing caps.
8. 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 assembly.
2 Pry the differential assembly and the differential bearing shims out of the differential housing.
3 Remove the special tool.
9. Using the special tools, remove the differential bearings.
10. If necessary, disassemble the differential assembly.
11. Using the special tool, hold the pinion flange to remove and discard the pinion nut.
12. Index-mark the pinion flange to the drive pinion stem.
13. Using the special tool, remove the pinion flange.
14. Use a screwdriver to force up the metal flange of the drive pinion oil seal. Install gripping pliers and strike with a hammer to remove the drive pinion oil seal.
15. Remove the drive pinion oil seal deflector, drive pinion oil seal slinger, the outer pinion bearing and the drive pinion collapsible spacer.
16. Using the special tool and a soft-faced hammer, remove the differential pinion gear from the differential housing.
17. Using the special tool and a press, remove the drive pinion inner bearing.
1 Position the special tool under the drive pinion inner bearing.
2 Using a press, remove the inner drive pinion bearing and shim.
18. Using a brass drift and a hammer, remove the differential drive pinion bearing cups from the differential housing. Tap alternately on each side of the cup to prevent them from cocking in the bore.
19. Inspect the differential case for wear or damage. If necessary, disassemble the differential case.
Installation
1. Using the special tool, install the differential drive pinion bearing cups.
1 Position the bearing cups on the special tool.
2 Position the special tool and the differential drive pinion bearing cups in the differential housing.
3 Tighten the special tool to fully seat the differential drive pinion bearing cups in the bores.
2. NOTE: If a feeler gauge of the specification shown can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.
Make sure the differential pinion bearing cups are correctly seated.
3. NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.
Install the drive pinion bearings and special tools as shown.
4. NOTE: This step duplicates drive pinion bearing preload.
Thread the special tool onto the screw and tighten to the specification shown.
^ Tighten to 2.2 Nm (20 inch lbs.).
5. CAUTION: Position the adapter so it does not contact the housing.
CAUTION: Offset the special tool to obtain an accurate reading.
Rotate the special tool several half turns to seat the drive pinion bearings. Position the special tool as shown.
6. 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 differential bearing cap bolts.
- Tighten to 105 Nm (77 ft. lbs.).
7. 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.
^ Notice the plus (+), minus (-) or zero (0) paint marking on the drive pinion stem and adjust the thickness of the new shim. If the marking is plus (+), subtract the number from the gauged shim thickness. If the marking is minus (-), add the number to the gauged shim thickness.
8. Remove all of the special tools.
9. CAUTION: Use the same drive pinion bearings and the 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 inner pinion bearing on the drive pinion gear stem.
10. Using the special tools and a suitable press, firmly seat the drive pinion bearing adjustment shim and inner pinion bearing on the drive pinion gear stem.
11. CAUTION: Make sure the splines on the drive pinion gear stem are free of burrs. If burrs are evident, remove them using a fine crocus cloth.
Place a new differential drive pinion collapsible spacer on the drive pinion gear stem against the pinion stem shoulder.
12. Install the outer pinion bearing and the drive pinion oil seal slinger.
13. CAUTION: Installation without the correct tool can result in early drive pinion seal failure.
CAUTION: If the drive pinion seal becomes misaligned during installation, remove it and install a new drive pinion seal.
NOTE: Coat the drive pinion seal lips with grease.
Using the special tool, install the new drive pinion seal.
14. Install the drive pinion gear with the differential drive pinion collapsible spacer in the differential housing.
15. Position the pinion flange.
1 Lubricate the pinion flange splines with grease.
2 Align the pinion flange.
16. Using the special tool, install the pinion flange.
17. CAUTION: Do not, under any circumstance, loosen the pinion nut to reduce drive pinion bearing preload. If it is necessary to reduce drive pinion bearing preload, install a new differential drive pinion collapsible spacer and pinion nut.
CAUTION: Remove the special tool while taking drive pinion bearing preload readings with the Nm (inch lbs.) torque wrench.
Use the special tool to hold the pinion flange while tightening the pinion nut.
^ Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (inch lbs.) torque wrench.
18. Tighten the pinion nut to set the drive pinion bearing preload.
19. Press the left and right differential bearing on the differential assembly.
1 Position the differential bearing.
2 Using the special tool, press the differential bearing on the differential assembly.
20. Install the differential assembly.
21. Install a differential bearing shim of the thickness shown on the LH side of the differential case.
22. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.
Install the left bearing cap and loosely install the bearing cap bolts.
23. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.
Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.
24. Install the right bearing cap and bolts.
25. Tighten the 4 differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).
26. Rotate the differential case to make sure it turns freely.
27. Install the special tool at the 12 o'clock position.
28. Using the special tools, measure the differential ring gear backlash at 4 equally spaced points.
1 Attach the special tool.
2 Position the special tool tip centrally on a drive tooth.
3 Zero the indicator.
4 Turn the differential ring gear without turning the drive pinion gear. Record the indicator reading. The allowable backlash is 0.203 - 0.305 mm (0.008 - 0.012 inch) and must not vary more than 0.101 mm (0.004 inch) between points measured. A backlash variation of more than 0.101 mm (0.004 inch) between points checked indicates gear/case runout.
- To correct for a high or low backlash, proceed as follows.
29. To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount.
Refer to the tables when adjusting the backlash.
Differential Shim Size Chart - 4067 (part 1):
Differential Shim Size Chart - 4067 (part 2):
Differential Shim Size Chart - 4067 (part 3):
Differential Shim Size Chart - 4067
30. Remove the 4 differential bearing cap bolts.
^ Remove the differential assembly.
31. Measure the thickness of the selected right and left bearing shims.
32. To establish differential bearing preload, increase both the left and right differential bearing shim thickness by 0.203 mm (0.008 inch).
33. CAUTION: To avoid galling the case, insert shims with a light coating of grease before installing the differential assembly. If not carried out in this order, the aluminum housing can be damaged.
Place the differential bearing shims in the differential housing.
34. Install the special tools.
35. CAUTION: Overspreading may 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 spreading the differential housing to the specification.
3 Remove the special tool.
36. Install the differential assembly.
1 Position the differential bearing cups on the differential bearings.
2 Lower the differential assembly in place between the differential bearing shims.
37. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.
Install the differential bearing caps and the differential bearing cap bolts in their original locations and positions.
38. Loosen and remove the special tool.
39. Tighten the 4 differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).
40. Install the special tool at the 12 o'clock position.
41. Using the special tools, recheck the ring gear backlash.
42. Apply marking compound and rotate the differential assembly 5 complete revolutions.
43. Verify an acceptable pattern check.
44. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.
CAUTION: Install the differential housing cover within 15 minutes of applying the silicone material.
CAUTION: Allow the sealant to cure for one hour before filling the axle with lubricant.
Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.
^ Use silicone gasket and sealant.
45. Install the differential housing cover.
46. Fill the axle assembly with the specified lubricant.
47. Install the rear axle assembly.