Differential
DIFFERENTIALDISASSEMBLY
1. Remove differential bearing cones (ring gear and diff. case side) using Tool C-293-PA, Adapters C-293-45, and Tool 4996 (Fig. 69) (Fig. 70).
2. Using a suitable screwdriver, pry off and remove speedometer drive gear (Fig. 71)(Fig. 72).
3. If servicing only pinion and side gears, remove ring gear-to-case bolts at pinion shaft retainer only (Fig. 73). Remove pinion shaft retainer (Fig. 74). Discard and use NEW bolts upon assembly.
4. If servicing ring gear as well, remove remaining ring gear-to-case bolts and remove ring gear from case (Fig. 75).
5. Remove pinion shaft (Fig. 76).
6. Remove pinion gears, side gears, and thrust washers (Fig. 77) (Fig. 78) (Fig. 79).
ASSEMBLY
1. Install side gears, pinion gears, and thrust washers into case through opening and rotating into position (Fig. 80) (Fig. 81).
2. Install pinion shaft (Fig. 82).
3. If previously removed, install ring gear to differential case (Fig. 83).
4. Install pinion shaft retainer (Fig. 84). Install NEW ring gear-to-case bolts and torque to 81 Nm (60 ft. lbs.) torque (Fig. 85).
5. Install speedometer drive gear to case (Fig. 86). Note orientation of index tab.
6. Using Steel Block and Tool L-4440, press speedometer drive gear into position (Fig. 87).
7. Using an arbor press, Handle C-4171, and Tool L-4410, install differential side bearings to ring gear and case side (Fig. 88) (Fig. 89).
Measure and Adjust Side Gear End-Play
1. Rotate the assembly two full revolutions both clockwise and counterclockwise. Set up dial indicator as shown and record end play (Fig. 90) (Fig. 91). Rotate side gear 90 degrees and take another measurement. Again, rotate side gear 90 degrees and record a final measurement.
2. Using the smallest end play recorded, shim that side gear to within 0.001 to 0.013 inch. The other side gear should be checked using the same procedure.
CAUTION: Side gear end play must be within 0.001 to 0.013 inch. Five select thrust washers are available: 0.027, 0.032, 0.037, 0.042, and 0.047 inch.