Differential Assembly: Disassembly
- Remove differential assembly. See DIFFERENTIAL ASSEMBLY under REMOVAL & INSTALLATION. Remove cover. Install differential in Bench-Mounted Holding Fixture (T57L-500B). Mount Dial Indicator (TOOL-4201-C) on axle housing fixture. Measure and record ring gear runout and backlash. See Fig 1 .
- Ensure ring gear runout and backlash variation between teeth are within specification. See AXLE ASSEMBLY SPECIFICATIONS . Replace ring gear and pinion if backlash variation is excessive. Mark differential bearing caps for reassembly reference.
- Loosen differential bearing cap bolts and bearing caps. Install Carrier Spreader (TOOL-4000-E) and Adapters (T93P-4000-A) on differential housing. See Fig 2 . Install dial indicator on Bracket (D78P-4201-F). Position dial indicator tip in carrier spreader adapter hole.
- Zero dial indicator, and tighten spreader to .030" (.762 mm). Remove bearing cap bolts and bearing caps. Using wood blocks to prevent damage to housing, pry out differential assembly and remove shims. Remove differential housing spreader. Remove differential side bearings using Bearing Remover (T70P-4221-A). Remove pinion nut and companion flange.
- With a soft-face hammer, drive pinion out of front bearing cone and remove through rear of housing. Remove pinion seal. Remove front bearing. Remove rear pinion bearing if damaged. Mount bearing puller on pinion, and press pinion from bearing. Remove pinion shim from behind bearing. Measure and record shim thickness.
- Bearing cups in housing may be removed using brass drift and hammer. Tap alternately on each side of bearing cup during removal to prevent bearing cup from binding in housing.
- If ring gear runout exceeds .004" (.10 mm), install differential assembly with bearings and cups in housing without pinion assembly. Install a .265" (6.73 mm) shim on left side of differential assembly. Install left differential bearing cap and bolts finger tight.
- Apply pressure toward left side of ring gear to ensure bearing is seated in bearing cup. Shim right side until slight drag is felt when inserting shim. Install right differential bearing cap and bolts. Tighten bolts to 70-85 ft. lbs. (95-115 N.m). Rotate differential assembly to ensure free rotation.
- Install dial indicator, and check ring gear runout. If runout is less than .004" (.10 mm), excessive runout was caused by improper bearing preload. If runout still exceeds .004" (.10 mm), remove differential assembly.
- Mark ring gear and differential assembly for reassembly reference. Remove ring gear bolts. Tap ring gear from differential case. Install differential assembly in housing.
- Recheck runout on differential carrier case flange. If runout is less than .004" (.10 mm), install new ring gear and pinion. If runout still exceeds .004" (.10 mm), inspect differential case or bearings for damage.
- If bearings are not damaged, replace differential case and bearings. Remove differential side bearings with a puller. Mark differential case and ring gear for reassembly reference. Remove pinion gears, side gears and thrust washers.
NOTE:
Note direction of arrows on differential bearing caps for installation reference. Mark position of shims, bearing cups and differential bearing caps for reassembly reference.
NOTE:
After removing pinion nut, but before removing flange, mark pinion stem in relation to companion flange for reassembly reference. If a new gear set is being installed, this is not necessary.
NOTE:
DO NOT remove pinion bearing cups unless damaged. If replacing bearing cups, bearings must also be replaced.