Differential Case Assembly - M220 Rear Axle: Notes

REMOVAL 

1. Raise and support the vehicle

   Refer to HOISTING, STANDARD PROCEDURE .

2. Remove the differential drain plug and drain the fluid.
3. Remove the differential cover. Refer to REMOVAL AND INSTALLATION .
4. Remove the axle shafts. Refer to REMOVAL AND INSTALLATION .
5. Remove the axle locker switch. Refer to REMOVAL AND INSTALLATION .

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   1 - Differential Bearing Cap Bolts

   2 - Differential Bearing Cap Bolts

6. Mark the bearing caps and the differential housing so the caps can be reinstalled in their original positions.
7. Loosen the differential bearing cap bolts.

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   1 - Spreader

   2 - Dial Indicator And Mounting

   3 - 90° Dial Indicator Tip

8. Position the (special tool #W-129-B, Spreader, Differential) with (special tool #6987B, Adapter Kit, Axle Spreader) on the differential housing locating holes. Install the hold-down clamps and tighten the turnbuckle finger-tight.
9. Install the (special tool #C-3288-B, Set, Alignment Pins) on the left side of the differential housing. Attach the (special tool #C-3339A, Set, Dial Indicator) with the SP-1917 equivalent 90° dial indicator tip to the pin. Load the SP-1917 or equivalent 90° dial indicator tip against the opposite side of the differential housing and zero the dial indicator.
10. Spread differential housing while measuring the distance with the dial indicator.
    NOTE:

    Never spread the differential housing over 0.50 mm (0.020 in.). Failure to follow these instructions will damage the housing. 

11. Remove the dial indicator.

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    1 - Differential Bearing Cap Bolts

    2 - Differential Bearing Cap Bolts

12. Holding the differential case in position, remove the differential bearing cap bolts.

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    1 - Differential Bearing Cap Bolts

    2 - Differential Bearing Cap

    3 - Axle Locker Coil Anti-rotation Bracket

13. Remove the axle locker coil anti-rotation bracket from the bearing cap, remove both bearing caps.

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    1 - Differential Case

    2 - Differential Housing

    3 - Differential Bearing Cup and Spacer

14. Remove the differential case from the differential housing and tag the differential bearing cup and shim locations.
    NOTE:

    Non-locker rear differential case assembly shown for bearing clarity.

CLEANING: 

• Clean the differential housing cavity with flushing oil, light engine oil or lint free cloth.
  NOTE:

  Do not use water, steam, kerosene or gasoline for cleaning.

INSTALLATION 

During installation, torque the fasteners to the specifications in the torque table(s) below.

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1. Install the differential case into the differential housing with the differential bearing cups and shims in their original locations.
   NOTE:

   Non-locker rear differential case assembly shown for bearing clarity.

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   1 - Differential Bearing Cap Bolts

   2 - Differential Bearing Cap

   3 - Axle Locker Coil Anti-rotation Bracket

2. Install the bearing caps in their original locations and install and center the coil anti-rotation bracket.

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   1 - Differential Bearing Cap Bolts

   2 - Differential Bearing Cap Bolts

3. Loosely install the differential bearing cap bolts.
4. Remove the differential housing spreader.
5. Tighten the bearing cap bolts in a criss-cross pattern to the proper torque specification.
6. Install the axle shafts. Refer to REMOVAL AND INSTALLATION .
7. Install the axle locker switch. Refer to REMOVAL AND INSTALLATION .
8. Install the differential cover. Refer to REMOVAL AND INSTALLATION .
9. Fill the differential with the specified fluid. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
10. Remove the support and lower the vehicle.

TORQUE SPECIFICATIONS