Inspection

1. Check differential gear tooth contact and replace any gear that is worn or damaged.
2. Check bearings and races and replace if worn, damaged or discolored.

Fig. 4 Measuring drive shaft spline freeplay:

3. Install side gear (with circlip on front differentials) onto splined end of axle shaft. Install assembly in vise, Fig. 4. Freeplay should not exceed .020 inch on rear differentials; .024 inch on front differentials.
4. Inspect differential pinion and pinion shaft and replace if worn or seized.
5. On limited slip differentials, proceed as follows:
a. Clean all components in a suitable solvent.
b. Inspect sliding and mating surfaces of clutch plate and pressure ring for pitting or damage.
c. Inspect contact surfaces of friction plates, friction discs, spring plates and spring discs. If any signs of seizure, severe friction or color from heat damage, replace components as required. Worn area around circumference of friction surfaces is due to spring plate and spring disc and wear is not abnormal.
d. Check the six projections on the inner circumference of the friction disc for nicks and dents, then repair as necessary using a suitable oil stone or replace as necessary.
e. Check the four projections on the outer circumference of friction disc for nicks and dents, then repair as necessary using a suitable oil stone or replace as necessary.
f. Inspect the sliding surfaces of the thrust washers and differential case, spring contacting surfaces of differential case, contacting surfaces of pressure rings, sliding surface of thrust washers and sliding surface of hole in side gears and repair as necessary using a suitable oil stone.
g. Check spherical surface of pinion gears and I.D. of pressure rings, then the V-shaped groove in the pressure rings and pinion shaft. Check O.D. of pinion shaft and hole in pinion gear, then the outer and inner circumference of differential case. Inspect sliding surface of thrust block, then if any damage is found on the preceding components, repair as necessary using a suitable oil stone or replace as necessary.
h. Inspect friction plates, friction discs, spring discs and spring plates for flatness using a suitable dial indicator. If found to be worn more than .003 inch on friction plate or .004 inch on clutch plate, replace worn components.