Cleaning & Inspection

Fig. 8 Differential case runout check:

1. Clean components in suitable solvent and blow dry with compressed air, noting the following:
a. Do not use brush when cleaning bearings.
b. Do not "spin dry" bearings as they will be damaged.
2. Inspect gears for cracks, chipped or broken teeth, wear and scoring. Replace gears that are damaged or excessively worn. Ring gear and pinion must be replaced as an assembly. If differential pinions are defective, they should be replaced as a set along with pinion shaft, not individually, to maintain proper backlash.
3. Inspect differential case for cracks, damage, distortion, and worn or scored side gear bores and bearing surfaces. Replace case if damaged or scored.
4. Check differential case runout as follows:
a. Prior to removing side bearings and shim packs, mount case assembly in housing, spreading housing as outlined during disassembly. Do not spread housing more than 0.020 inch as housing will be permanently distorted.
b. Remove spreader, install bearing caps and mount suitable dial indicator on housing with plunger bearing against machined ring gear flange.
c. Rotate case and read runout on dial indicator. If runout exceeds 0.003 inch, case much be machined or replaced.
d. If case runout is less than 0.003 inch but ring gear runout measured during disassembly exceeded 0.006 inch, install ring gear on case with point of maximum runout 180° away from original position, then recheck ring gear runout.
e. If runout is reduced to an acceptable value after repositioning ring gear, assembly can be reused.
5. Inspect axle housing for damaged or scored bearing bores, cracks, distortion and damage. Repair or replace housing as needed.
6. Inspect bearing rollers and races for pitting, scoring, overheating and damage.
7. Mate each bearing with race and check operation.
8. Replace any bearing assembly that is damaged, excessively worn, or that fails to operate smoothly.