Disassembly And Assembly

DISASSEMBLY 

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1. Remove the O-ring seal from the carrier side.

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2. Remove the O-ring seal from the gear side.

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3. Remove right side differential bearing using (special tool #C-293-PA, Puller, Press), (special tool #C-293-37, Block Set, Puller) and (special tool #C-4996, Adapter, Plug).

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4. Install indexing marks (1) to the ring gear and the differential case prior to disassembly.

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5. Remove and discard the ring gear bolts (1) from the differential case, do not reuse the bolts.

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6. Separate the ring gear assembly (1) from the case (2).

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7. Install additional indexing marks to the ring gear and the left side differential case prior to disassembly.
8. Use suitable bolts (1) to assist in separating the ring gear and left side case assembly.

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9. Separate the ring gear (2) from the left side case assembly (1).
   WARNING:

   Use tongs or welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.

   CAUTION:

   Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.

10. Use a bearing heater to aid in removing the large left side differential bearing race.
11. Once sufficiently heated, support the left side case assembly on wooden blocks with the race facing downward.
12. Using a dead blow style hammer, strike the back side of the case until the bearing race has moved approximately 12mm (.5 inches).
13. Use a brass drift to finish removing the bearing race from the case.

ASSEMBLY 

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1. Separate the ring gear (2) from the left side case assembly (1).
   WARNING:

   Use tongs or welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.

   CAUTION:

   Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.

2. Use a bearing heater to aid installation of the large left side differential bearing race.
3. Once sufficiently heated, drop the NEW  bearing race into the case bore.
4. Use a brass drift to finish installing the race.

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5. Combine the left side case (2) and the ring gear (1).

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6. Align the ring gear assembly and the case using the index marks (1).

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7. Install the NEW  ring gear bolts (1) to the differential case. Tighten to 97 N. m (72 ft. lbs.)

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8. Install the side differential bearing (2) using a press and (special tool #8445-1, Installer, Cup) (1).

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9. Install the O-ring seal to the carrier side.

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10. Install the O-ring seal to the gear side.