Standard Assembly

Fig. 1 Exploded view of Borg Warner 4 pinion standard differential:

1. Remove ring gear attaching bolts, then the ring gear from differential housing.
2. Drive out three differential pinion cross shaft retaining pins, Fig. 1, using a punch.
3. Drive three differential pinion shafts from housing using a punch. Remove long pinion shaft first.
4. Scribe alignment marks on differential case halves, then separate differential case halves by holding one side and tapping against other side with a soft hammer.
5. Remove four differential pinions, side gears and thrust washers from housing.
6. Remove differential case bearings using puller tool J-22888-20 or equivalent.

Note: When removing the side differential case bearings, you may discover that recommended tool J 22888-20 does not work because some limited-slip differential cases do not have notches for the jaws of the puller. Use tool J 34168 to press the bearing off the case.

7. Inspect components as outlined under CLEANING & INSPECTION and replace as required.
8. Lubricate all gears and thrust washers with appropriate lubricant.
9. Install side gear thrust washers in differential case. Hold washers in position with grease.
10. Install side gear in large half of differential case.
11. Install thrust block in case, then drive long pinion cross shaft through case, pinion and thrust block bores. Align retainer pin hole with hole in case. Use caution not to damage differential pinion thrust washers.
12. Install two remaining pinions and thrust washers in large half of differential case. Drive two short pinion cross shafts through case, pinions and into thrust block bores. Align retainer pin hole with hole in case.
13. Install three cross shaft retaining pins through case and shafts. Ensure long cross shaft retaining pin extends 6 mm from case.
14. Install remaining side gear and thrust washer in small case half.
15. Install side gear through case bore, then align case halves on retaining pin. Rotate side gear to ensure gears are meshing.
16. Install ring gear and ring gear attaching bolts onto housing. Torque ring gear attaching bolts to 101 ft. lbs.
17. Press differential bearings on housing journals using tool J-21784 or equivalent.