Differential Assembly: Testing and Inspection

If noises or roughness such as chatter are present when turning corners, the probable cause is incorrect or contaminated lubricant.

Before any differential is removed and disassembled for chatter complaints, the correctness of lubricant should be determined.

Verify the axle has the specified quantity of Hypoid Gear Lubricant, C6AZ-1 9580-E (ESW-M2C105-A) or equivalent and 0.236L (8 ounces) of Additive Friction Modifier, C8AZ-19B546-A (EST-M2C118-A) or equivalent friction modifier for rear axles and 0.059L (2 oz) of Additive Friction Modifier C8AZ-19B546-A (EST-M2C118-A) or equivalent friction modifier for front drive axles. Warm the axle up and recheck for chatter by making a minimum of ten figure- eight type turns.

If this is unsuccessful, a complete lubricant drain, flush and refill will usually correct chatter. The following procedure is recommended to ensure that the system is flushed of old lubricant.

1. Warm the lubricant by vehicle road operation or five minutes of operation in gear with both rear wheels off the ground on a hoist.

CAUTION: Never place the transmission in gear with the engine running when only one wheel of a limited slip differential equipped vehicle is raised. The vehicle might drive itself off the jack and cause damage or injury.

2. Drain lubricant while warm. Remove cover plate to drain completely. If cover plate is removed, it will be necessary to replace gasket at this time.

FIG. 5 Cover Plate Flat Mounting Surface:

3. Figure 5 shows the flat mounting surface cover plate on Dana design axles. This cover plate requires the use of Silicone Rubber E7TZ-19562-A (ESL-M4G273-A) or equivalent rather than a gasket.

The cover face of the carrier and the flat surface of the cover plate must be free of any oil film or foreign material.

Apply Silicone Rubber E7TZ-19562-A (ESL-M4G273-A), or equivalent to cover plate surface. Ensure that the sealer bead is laid on the inside of the cover screw holes. The bead is not to pass through the holes or outside of the holes.

The bead is to be 3.18-6.35mm (1/8 inch to 1/4 inch) wide.

Assemble two cover screws into cover at 8 o'clock and 2 o'clock position. Use these two holes to guide cover plate into position on the carrier.

Install remaining screws. Tighten alternately and evenly. Tighten screws to 41-54 N m (30-40 ft- lbs.).

Allow one hour cure time before filling carrier with the proper amount of specified lubricant and vehicle operation.

4. Refill axle with specified lubricant.

5. Operate the vehicle for approximately 16 Km (10 miles), making at least ten figure eight turns to flush the old lubricant out of the clutch packs.

6. Repeat steps 2, 3 and 4, making sure to replace cover gasket, if required, in Step 2.

7. It is possible that a slight chatter, requiring additional vehicle operation may remain after Step 5. If chatter still persists after 160 Km (100 miles) of operation, or remains severe after Step 5 above, disassembly and repair will be necessary.