Disassembly & Inspection

Fig. 1 Typical differential carrier:

1. Remove side retainers, Fig. 1.
2. Remove differential case from carrier.
3. When replacing side bearing, extract bearing outer race from side retainer.
4. Loosen drive pinion nut, holding companion flange and pull off companion flange using a suitable puller.
5. Press drive pinion from carrier using a press. Remove drive pinion with rear bearing cone, bearing spacer and adjusting washers.
6. Remove oil seal.
7. Remove pinion bearing with pinion bearing spacer and front bearing cone.
8. Press rear bearing inner race from drive pinion.
9. Drive out front and rear bearing outer races and remove bearing.
10. Remove ring gear.
11. Remove pinion mate shaft lock pin from ring gear side. Lock pin is caulked at pin hole mouth on differential case.
12. Remove pinion mate shaft and the pinion mate gears, side gears and thrust washers.

INSPECTION

Thoroughly clean all disassembled parts, and examine them to see that they are worn, damaged or otherwise faulty, and how they are affected. Repair or replace all faulty parts, whichever is necessary.
1. Check gear teeth for scoring, cracking or chipping, and make sure that tooth contact pattern indicates correct meshing depth. If any fault is evident, replace parts as required. Drive pinion and drive gear are supplied as a set; therefore, should either part be damaged, replace as a set.
2. Check pinion gear shaft, and pinion gear for scores and signs of wear, and replace as required. Follow the same procedure for side gear and their seats on differential case.
3. Inspect all bearing races and rollers for scoring, chipping or evidence of excessive wear.

Fig. 4 Measuring Pinion To Side Gear Backlash:

4. Inspect thrust washer faces. Small faults can be corrected with sandpaper. Inspect pinion mate-to-side gear backlash, Fig. 2. If clearance between side gear and thrust washer exceeds .0039-.0079 inch�MDBO/MDNM (less than .0059 inch on models), replace thrust washers.
5. Inspect carrier and differential case for cracks or distortion. If either condition is evident, replace faulty parts.