Except Model 70

Fig. 6 Exploded view of differential. Model 35:

Fig. 7 Exploded view of differential. Model 44:

Fig. 8 Exploded view of differential. Model 60:

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 models 30 and 35 axles, proceed as follows:
a. Install bearing remover tool 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 degrees 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.

Fig. 9 Removing differential bearing:

7. On model 44 axles, proceed as follows:
a. Install bearing remover tool 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.
d. Install puller J-22888 or equivalent, 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. Install bearing removal tool Nos. DD-914-P, DD-914-8, DD-914-62, DD-914-7 and DD-914-42 or equivalents.
b. Ensure adapter rings do not cause force on bearing races.
c. Remove side gear and thrust washers.
d. Repeat above steps to remove opposite bearing.
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 to 45-60 ft. lbs. for models 30, 35 and 44 axle or 110-115 ft. lbs. for 1987-90 model 60 axle or 81 ft. lbs. for 1991 models 60 axle in crossing pattern.
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 0.015 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. 10 Side bearing clearance check:

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 that 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 19-21 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 axle assembly.
23. Remove dial indicator, bearing caps and differential assembly from housing, keeping side bearing races in proper position for assembly.