- Remove bolts, speed sensor assembly and "O" ring. Remove differential case cover bolts in a crisscross pattern. Remove differential case cover. Remove breather plate from differential case cover (if necessary). See Fig 1.
- Remove differential carrier assembly from differential case. Remove oil cooler nuts, oil cooler, "O" rings and oil guide pipe.
- Using hammer and chisel, cut lock nut tab and pry away from drive pinion. Insert 32-mm hex bit socket into gear end of drive pinion.
- Remove lock nut, thrust washer and drive pinion hub. Remove oil seal and thrust washer. Using soft-faced hammer, tap drive pinion from pinion bearing on front of drive pinion. Remove drive pinion, pinion spacer and thrust washers.
- Inspect pinion bearings. If replacing pinion bearing on drive pinion, use press and bearing remover to press bearing from drive pinion. Remove drive pinion thrust shim from drive pinion.
NOTE:
If pinion bearings are replaced, bearing races must also be replaced.
- To remove pinion bearing races from differential case, pry bearing race from differential case. Bearing race may also be removed by heating differential case to 212°F (100°C) and removing bearing race. DO NOT heat differential case to more than 212°F (100°C). Remove thrust washers, located below bearing races, from differential case.
- Inspect differential carrier bearings. If replacing differential carrier bearings, use press and bearing remover to press bearing from differential carrier.
NOTE:
If differential carrier bearings are replaced, bearing races must also be replaced.
- To remove differential carrier bearing races, pry bearing race from differential case or differential case cover. Bearing race may also be removed by heating differential case or differential case cover to 212°F (100°C) and removing bearing race. DO NOT heat differential case or differential case cover to more than 212°F (100°C). Remove thrust shim(s), located below bearing races, from differential case or differential case cover.
NOTE:
Thrust shim must be replaced if bearing race was removed from differential case or differential case cover.
NOTE:
Pinion gear backlash must be checked to determine if differential carrier assembly must be replaced. Differential carrier bearings must be removed from differential carrier to measure pinion gear backlash.
- Mount differential carrier in "V" blocks with axle shaft and intermediate shaft inserted into side gears. See Fig 2. Using dial indicator, check pinion gear backlash. Pinion gear backlash should be .002-.006" (.05-.15 mm).
- Replace differential carrier assembly if pinion gear backlash is not within specification. Remove ring gear (if necessary).