See Figures 1, 2, 3 and 4
- Remove the cover and clean the lubricant from the internal parts.
- Using a dial indicator, measure and record the ring gear backlash and the runout. The backlash should be 0.008-0.015 in. (0.20-0.38mm); the runout should be less than 0.004 in. (0.10mm).
- Mark one differential bearing cap to insure it is installed in its original position.
- Loosen the differential bearing cap bolts.
- Using a prybar, carefully pry the differential carrier until the bearing cups and shims are loose in the bearing caps.
- Remove the bearing caps and the differential assembly.
- If necessary, remove the bolts holding the ring gear to the differential case. Using a hammer and a punch, strike the alternate bolt holes around the ring gear to dislodge it from the differential.
- If necessary, remove the exciter ring by striking it with a soft hammer.
- Remove the pinion shaft lock bolt from the differential case. Remove the differential pinion shaft, the pinion gears and the thrust washers.
- Remove the side gears and the thrust washers.
- Using a bearing puller, remove the bearings from the differential carrier.
- Remove the differential carrier assembly.
- Using a companion flange holding tool, remove the companion flange nut.
- Using a puller, separate the companion flange from the pinion gear.
- With a soft hammer, drive the pinion gear from the housing.
- Use a small prybar to remove the pinion gear oil seal from the housing.
- Remove the oil slinger and the front pinion bearing.
- Use a shop press to press the bearing cone from the pinion gear.
- Remove and record the shim from the pinion gear.
- Clean the differential components in solvent and use compressed air to dry them; do not use compressed air on the bearings-dry them with shop towels.
- Check the components for wear or damage; replace them if necessary.
- Inspect the bearings and bearing cups for wear, cracks or scoring; replace them if necessary.
- Inspect the differential side and pinion gears for wear, cracks or chips; replace them if necessary.
- Inspect the ring and pinion gears for wear and/or damage; replace them if necessary.
- Inspect the differential case for cracks or damage; replace it if necessary.
See Figures 5 through 24
When replacing the ring and pinion gear, the correct shim thickness for the new gear set to be installed is determined by the following procedure using a pinion depth gauge tool set.
- Assemble the appropriate aligning adapter, the gauge disc and gauge block to the screw.
- Place the rear pinion bearing over the aligning tool and insert it into the rear portion of the bearing cup of the carrier. Place the front bearing into the front bearing cup and assemble the tool handle into the screw. Roll the assembly back and forth a few times to seat the bearings while tightening the tool handle, by hand, to 20 ft. lbs. (27 Nm).
The gauge block must be offset 45 degrees to obtain an accurate reading.
- Center the gauge tube into the differential bearing bore. Install the bearing caps and tighten the bolts to 70-85 ft. lbs. (96-115 Nm). Be sure to install the caps with the triangles pointing outward.
- Place the selected shim(s) on the pinion and press the pinion bearing cone and roller assembly until it is firmly seated on the shaft. Use the pinion bearing cone replacer and the axle bearing/seal plate.
- Place the collapsible spacer on the pinion stem against the pinion stem shoulder.
- Install the front pinion bearing and oil slinger in the housing bore and install the pinion seal on the pinion seal replacer. Using a hammer, install the seal until it seats.
- From the rear of the axle housing, install the drive pinion assembly into the housing pinion shaft bore.
- Lubricate the pinion shaft splines and install the companion flange.
- Using a companion flange holder, tighten the pinion nut to 160 ft. lbs. (217 Nm). Rotate the pinion gear occasionally to insure proper bearing seating.
- Using an inch-pound torque wrench, frequently measure the pinion bearing preload; it should be 8-14 inch lbs. (0.8-1.6 Nm) for used bearings or 16-29 inch lbs. (1.8-3.2 Nm) for new bearings.
If the preload is higher than the specification, tighten to the original reading as recorded. Never back off the pinion nut.
- If the bearings were removed, use a shop press to press them onto the differential case.
- Install the side gears and thrust washers. Install the pinion gears, the thrust washer, the pinion shaft and the pinion shaft lock bolt.
- Using a shop press, align the exciter ring tab with the differential case slot and press the ring gear and exciter ring onto the differential case. Install the bolts holding the ring gear to the differential case; tighten them to 100-120 ft. lbs. (135-162 Nm).
- Place the differential case with the bearing cups into the housing.
- On the left side, install a 0.265 in. shim. Install the bearing cap and tighten the bolts finger-tight.
- On the right side, install progressively larger shims until the largest can be installed by hand. Install the bearing cap.
- Tighten the bearing cap bolts to 70-85 ft. lbs. (95-115 Nm).
- Rotate the assembly to insure freedom of movement.
- Adjust the ring gear backlash.
See Figures 25 through 36
- Using a dial indicator, measure the ring gear and pinion backlash; it should be 0.008-0.015 in. (0.20-0.38mm). If the backlash is 0.001-0.007 in (0.025-0.178mm) or greater than 0.015 in (0.38mm), proceed to Step 3. If the backlash is zero, proceed to Step 2
- If the backlash is zero, add 0.020 inch (0.50mm) shim(s) to the right side and subtract the equal number of the same size shims from the left side.
- If the backlash is within specification, go the Step 7. If the backlash is 0.001-0.007 in (0.025-0.178mm) or greater than 0.015 in (0.38mm), increase the thickness of a shim on one side and decrease the same thickness of another shim of the other side, until the backlash comes within range.
- Install and tighten the bearing cap bolts to 80-95 ft. lbs. (109-128 Nm).
- Rotate the assembly several times to insure proper seating.
- Recheck the backlash; if not within specifications, go back to Step 1.
- Remove the bearing caps. Increase the shim sizes on both sides by 0.006 inch. (0.152mm). Make sure the shims are fully seated and the assembly turns freely. Use a shim driver to install the shims.
- Install the bearing caps and tighten to 80-95 ft. lbs. (109-128 Nm). Recheck the backlash; if not to specification, repeat this entire procedure.