Differential Case Replacement

Differential Case Replacement

Special Tools
* DT 49909 - Axle Housing Spreader Adaptors (195-218 mm Axles)
* J 8001 - Dial Indicator Set
* J 34178 - Spreader Gauge Adapter
* J 45222 - Axle Housing Spreader

For equivalent regional tools, refer to Special Tools (Tools and Equipment).

Removal Procedure

1. Remove the rear differential carrier cover. Refer to Rear Axle Housing Cover and Gasket Replacement (Service and Repair).
2. Install the J 45222 - spreader (2) and the DT 49909 - adapters (1).
3. Install the rear differential assembly in a vise.

Note:
* Preload the dial indicator and set to zero.
* DO NOT spread the differential carrier more than

4. Using the J 8001 - indicator set (2), and the J 45222 - spreader (1), spread the differential carrier just enough to remove the differential case assembly. DO NOT spread the differential carrier more than 1.02 mm (0.040 in).





Note: Mark the left and right bearing caps before removing them.

5. Remove the differential bearing caps (2) and the bolts (1)

Note: Steps 6 and 8 are for those vehicles equipped with the electronic locking differential.

6. Remove the electronic locking differential coil bracket
7. Remove the electronic locking differential grommet by passing it into the differential case.
8. Relocate the electronic locking differential wire and grommet to the side so that it is not damaged during the differential case removal.
9. Remove the differential case assembly from the axle housing.

Installation Procedure

1. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (Maintenance).
2. Install the differential case assembly in the differential carrier.

Note: Step 3 is for those vehicles equipped with the electronic locking differential.

3. Install the electronic locking differential coil wire and grommet in the differential housing.




4. Install the bearing caps (2) on the differential case.

Note: Step 5 is for those vehicles equipped with the electronic locking differential.

5. Install the electronic locking differential coil wire bracket on the side bearing caps.

Note: Do not torque the bearing cap bolts at this time. Hand tighten the bearing cap bolts.

6. Install the bearing caps and bolts.
7. Adjust the differential side bearing preload. Refer to Drive Pinion and Ring Gear Replacement (Service and Repair).
8. Adjust the backlash. Refer to Backlash Adjustment (Backlash Adjustment).
9. Perform the gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection (Gear Tooth Contact Pattern Inspection).

Caution: Refer to Fastener Caution (Fastener Caution).

10. Tighten the bearing cap bolts (1) to 63 Nm (46 lb ft).
11. Remove the J 45935 - fixture and the DT 49909 - adaptors from the front drive axle housing.
12. Install the rear differential carrier cover. Refer to Rear Axle Housing Cover and Gasket Replacement (Service and Repair).