Differential Case Replacement (250 mm Axle)
Differential Case Replacement (250 mm Axle)
Special Tools
* J-8001 - Dial Indicator Set
* J-36842 - Holding Fixture
For regional equivalent 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 (195/218 mm Axle) Rear Axle Housing Cover and Gasket Replacement (195/218 mm Axle)Rear Axle Housing Cover and Gasket Replacement (250 mm Axle) Rear Axle Housing Cover and Gasket Replacement (250 mm Axle).
2. Using the J-36842 - fixture, install the rear differential carrier in the vise.
3. Remove the differential oil cooler assembly. Refer to Differential Oil Cooler Replacement Differential Oil Cooler Replacement.
4. Loosen the differential case bearing cap bolts.
5. Position the 14 inch C clamp so that it is parallel with the ring gear.
6. Position the J-8001 - set (1) on the differential carrier.
Note: Compress the housing just enough to remove the differential case assembly. DO NOT compress the housing more than 0.254mm (0.01 inch.
7. Using a 14 inch C clamp, compress the rear axle housing just enough to remove the differential case assembly.
Note: Mark the left and right bearing caps before removing them.
8. Remove the differential bearing caps (2) and the bolts (1)
9. Remove the differential case using the following steps.
1. Place the proper size wrench on the ring gear bolt.
2. Protect the sealing surface of the rear axle housing by placing a piece of wood between the wrench and the rear axle housing.
3. Rotate the pinion flange counter clock wise to remove the differential case from the rear axle housing
10. Remove the differential case assembly (1) from the rear axle housing.
11. Remove the side bearing cups (2) and the shims (3).
12. If servicing the differential side bearings, refer to Differential Bearing Replacement (195/218 mm Axle) Differential Bearing Replacement (195/218 mm Axle)Differential Bearing Replacement (250 mm Axle) Differential Bearing Replacement (250 mm Axle).
13. If servicing the differential ring gear, refer to Drive Pinion and Ring Gear Replacement (195/218 mm Axle) Drive Pinion and Ring Gear Replacement (195/218 mm Axle)Drive Pinion and Ring Gear Replacement (250 mm Axle) Drive Pinion and Ring Gear Replacement (250 mm Axle).
Installation Procedure
1. Install the differential side bearings, if serviced. Refer to Differential Bearing Replacement (195/218 mm Axle) Differential Bearing Replacement (195/218 mm Axle)Differential Bearing Replacement (250 mm Axle) Differential Bearing Replacement (250 mm Axle).
2. Install the differential ring gear, if serviced. Refer to Drive Pinion and Ring Gear Replacement (195/218 mm Axle) Drive Pinion and Ring Gear Replacement (195/218 mm Axle)Drive Pinion and Ring Gear Replacement (250 mm Axle) Drive Pinion and Ring Gear Replacement (250 mm Axle).
3. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations [1][2]Fluid Type Specifications.
Note: Compress the housing just enough to install the differential case assembly. DO NOT compress the housing more than 0.254mm (0.01 inch.
4. Using a 14 inch C clamp, compress the rear axle housing just enough to install the differential case assembly.
5. Install the differential case assembly in the differential carrier.
6. Install the bearing caps (2) on the differential case.
Note: Do not torque the bearing cap bolts at this time. Hand tighten the bearing cap bolts.
7. Install the bearing caps and bolts.
8. Adjust the differential side bearing preload. Refer to Drive Pinion and Ring Gear Replacement (195/218 mm Axle) Drive Pinion and Ring Gear Replacement (195/218 mm Axle)Drive Pinion and Ring Gear Replacement (250 mm Axle) Drive Pinion and Ring Gear Replacement (250 mm Axle).
9. Adjust the backlash. Refer to Backlash Adjustment (195/218 mm Axle) Backlash Adjustment (195/218 mm Axle)Backlash Adjustment (250 mm Axle) Backlash Adjustment (250 mm Axle).
10. 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.
11. Tighten the bearing cap bolts (1) to 168 Nm (124 lb ft).
12. Remove the C clamp.
13. Remove the J-8001 - set (1).
14. Install the differential oil cooler assembly. Refer to Differential Oil Cooler Replacement Differential Oil Cooler Replacement.
15. Install the rear differential carrier cover. Refer to Rear Axle Housing Cover and Gasket Replacement (195/218 mm Axle) Rear Axle Housing Cover and Gasket Replacement (195/218 mm Axle)Rear Axle Housing Cover and Gasket Replacement (250 mm Axle) Rear Axle Housing Cover and Gasket Replacement (250 mm Axle).