Models 30, 35, 44 & 60

Fig. 3 Exploded View Of Models 60, 70 & 80 Drive Axle:

Fig. 8 Exploded View Of Differential:

Fig. 9 Exploded View Of Differential:

1. Support differential case and remove and discard ring gear bolts.
2. Remove ring gear from case, tapping with soft faced hammer. Do not pry gear from case as mounting surfaces will be damaged.
3. Drive out pin securing differential pinion shaft, then remove shaft.
4. Rotate side gear to roll differential pinions from case, and remove pinions and thrust washers, noting installation position for assembly.
5. Remove side gears and thrust washers from case, noting installation position.
6. On model 30 and 35 axles, proceed as follows:
a. Install bearing remover tool No. J-29721, or equivalent, on bearing and case.
b. Install two bearing adapters in remover tool base. Insert adapters into one side of tool base from top and position 180° apart.
c. Install remover tool button in differential case and center remover tool forcing screw in button.
d. Tighten remover tool forcing screw and remove bearing.
e. Repeat above steps to remove opposite bearing.
7. On model 44 axles, proceed as follows:
a. Install bearing remover tool No. J-22888, or equivalent, on case and bearing.
b. Position chamfered edges of remover tool between bearing inner race and case.
c. Tighten remover tool bolts until chamfered edges of tool are well under bearing race, then install puller button in case bore.

Fig. 11 Differential Bearing Removal:

d. Install puller onto remover, and center puller forcing screw in puller button.
e. Tighten puller forcing screw and remove bearing.
f. Repeat above steps to remove opposite bearing.
8. On model 60 axles, proceed as follows:
a. Using bearing removal tool Nos. DD-914-P, DD-914-8, DD-914-62, DD-914-7 and DD-914-42, or equivalents, remove differential bearings. Ensure adapter rings do not cause force on bearing races.
9. On all models, coat all components with specified lubricant prior to assembly. Components that are to be reused should be installed in original position to ensure proper operation.
10. Install side gears along with thrust washers in respective sides of case.
11. Install thrust washers on differential pinions using grease to adhere washers.
12. Position pinion assemblies in case 180° apart, then roll pinions into alignment with pinion shaft bores, ensuring thrust washers are in place.
13. Insert pinion shaft, aligning lockpin hole with hole in case, then secure shaft with new lockpin.
14. Support differential case, install ring gear and new ring gear bolts, then seat ring gear on case with suitable mallet.
15. Evenly torque ring gear bolts as follows:
a. On model 30 and 35 axles, torque to 70-90 ft. lbs.
b. On 1994-96 vans with model 60 axle, torque grade 8 bolts to 100-120 ft. lbs. or grade 9 bolts to 125-135 ft. lbs.
c. On 1994-96 pickups with model 60 axle, torque to 120-140 ft. lbs.
16. Press specified master gauge bearings or selected side bearings onto case, then place races over respective side bearings, if used.
17. Install spreader tool and dial indicator on axle housing and spread case .015 inch as outlined during disassembly, then remove dial indicator. Do not spread housing more than 0.015 inch as housing will be damaged. Leave spreader tool installed only long enough to perform necessary service to prevent permanent distortion.
18. Mount differential in housing, install bearing caps, and tighten cap bolts hand tight and remove spreader if installed.

Fig. 12 Side Bearing Clearance Inspection:

19. Mount suitable dial indicator on housing with plunger bearing against back of ring gear.
20. Pry differential case as far away from indicator as possible, inserting suitable lever between bearing race and housing.
21. Ensure indicator plunger is still in contact with gear, then zero indicator.
22. Pry differential toward indicator, as far as possible, then record dial indicator reading. Repeat steps 19 through 21 until same reading is obtained each time. Recorded reading indicates shim thickness necessary to take up clearance between side bearings and housing. Shim pack thickness to be placed on bearing hubs between side bearings and case will be determined during "Final Assembly and Adjustment."
23. Remove dial indicator, bearing caps and differential assembly from housing, keeping side bearing races in proper position for assembly.