Standard Differential

DIFFERENTIAL

REMOVAL
1. Remove lubricant fill hole plug from the differential housing cover.
2. Remove differential housing cover and drain the lubricant from housing.
3. Remove axle shafts.





4. Remove adjuster lock bolts (1) and adjuster locks (2).
5. Mark bearing caps (4) left and right for installation reference.
6. Remove bearing cap bolts and remove bearing caps.





7. Loosen differential bearing adjusters (2) (4) with Spanner Wrench 8883.
8. Remove differential case from the housing.
9. Remove bearing cups and tag them left and right for installation reference.

DISASSEMBLY





1. Remove pinion shaft (2) with a hammer and punch from the side with the hole in the pinion shaft.





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





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





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

ASSEMBLY

NOTE: If the 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) into the differential window (1) and side gears (2). Rotate the pinion gear to the back of the case.
4. Install other pinion gear and thrust washer. Rotate the gears to align hole in the pinion gears with hole in the differential case.





5. Slide pinion shaft (4) into the case and through the pinion gears (3). Tap the shaft to seat the pinion shaft snap-ring (1) into the case.

INSTALLATION





1. Clean the housing (1) cavity with a flushing oil, light engine oil or lint free cloth.

CAUTION: Do not use water, steam, kerosene or gasoline for cleaning.

2. Lubricate differential case bearing.
3. Install differential case with bearings cups into the housing.

NOTE: A light coat of grease on the cups will hold them in place during installation.

4. Install bearing caps (2) and bolts. Tighten the bearing cap bolts finger-tight.
5. Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained.





6. Holding the differential case toward the pinion gear, turn bearing adjusters with Spanner Wrench 8883 (1) until they make contact with the differential bearings/cups.
7. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash.
8. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
9. Tighten pinion gear side adjuster firmly against the differential case bearing cup.
10. Rotate the pinion several times to seat the differential bearings.
11. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup.
12. Tighten pinion gear side adjuster until it just makes contact with the bearing cup.
13. Tighten pinion gear side adjuster an additional:
^ New Bearings 6 Adjuster Holes
^ Original Bearings 4 Adjuster Holes

14. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.





15. Tighten bearing cap bolts to 165 Nm (122 ft. lbs.).
16. Tighten adjuster (2) lock bolts (3) to 25 Nm (18 ft. lbs.).
17. Measure ring gear backlash and check gear tooth contact pattern.
18. Install axle shafts.
19. Install differential housing gasket and cover. Tighten cover bolts to 40 Nm (30 ft. lbs.).
20. Fill axle with lubricant.
21. Install fill plug and tighten to 32 Nm (24 ft. lbs.).