Differential

DIFFERENTIAL

REMOVAL





1. Remove differential cover.
2. Remove axle shafts.
3. Remove ABS sensor from housing.
4. Mark differential housing and bearing caps (3) for installation reference.





5. Remove bearing adjuster lock bolt (3) from bearing caps.





6. Loosen differential bearing cap bolts.
7. Loosen differential bearing adjusters through the axle tubes (1) with Wrench C-4164 (3).
8. Hold differential case while removing bearing caps and adjusters.
9. Remove differential case and tag differential bearing cups and adjusters to indicate location.
10. Clean housing cavity with flushing oil, light engine oil or a lint free cloth.

Note: Do not use steam, kerosene or gasoline to clean the housing.

DISASSEMBLY





1. Rotate one pinion gear (2) with thrust washer (3) to the differential window (1). Remove gear and thrust washer.





2. Rotate remaining pinion gear (3) with thrust washer (2) to the differential window (1). Remove gear and washer.





3. Remove differential side gears (1) (2) and thrust washers.

ASSEMBLY

Note: If same gears and thrust washers are being used, install them into their original locations.





1. Lubricate all differential components with axle lubricant.
2. Install differential side gears (2) and thrust washers.





3. Install first pinion gear (3) with thrust washer into differential window (1) and side gears (2). Rotate pinion gear into the case.
4. Install remaining pinion gear and thrust washer. Rotate gears to align hole in the pinion gears with hole in the differential case.
5. Slide pinion shaft into the case and through the pinion gears to align the gears.

INSTALLATION
1. Apply a coat of hypoid gear lubricant to differential bearings, bearing cups and threaded adjusters.

Note: Grease can be used to keep the adjusters in position.

2. Install differential assembly into the housing.
3. Install differential bearing caps in their original locations.
4. Install bearing cap bolts and tighten the upper bolts to 14 Nm (10 ft. lbs.). Tighten lower bolts finger tight until the bolt head is seated.
5. Perform differential bearing preload and adjustment procedure.





6. Tighten bearing cap bolts (2) to 136 Nm (100 ft. lbs.). Install adjuster locks and tight adjuster lock bolts (3) to 10 Nm (95 inch lbs.).
7. Install axle shafts.