Front Differential

1. Remove axle assembly from vehicle.
2. Loosen bolts retaining carrier to axle arm and drain fluid.
3. Remove right hand slip yoke and stub shaft.
4. Remove bolts attaching support arm to carrier, then remove carrier assembly.

Fig. 2 Exploded View Of Model 28-1FS & 35-1FS Axles:

5. Place carrier into holding fixture tool No. T57L-500-B, or equivalent, using adapter plate tool No. T90T-4000-A, or equivalent, and spacers, then remove and clean all gasket surfaces.
6. Remove bearing caps. Note matched numbers or letters stamped on the cap and carrier assembly; these numbers or letters must be matched during assembly. They may either be stamped vertically, horizontally or in some instances both vertically and horizontally.
7. Mount spreader tool No. 4000-E and tool No. T80T-4000-B, or equivalents, onto carrier assembly.
8. Position a dial indicator onto carrier, then spread housing.

NOTE: Do not spread housing more than 0.010 inch.

9. Remove differential case from carrier. It may be necessary to pry case from carrier with suitable pry bars. Use care to avoid damaging machined surfaces.
10. Remove and tag bearing cups to indicate which side of carrier they were removed from, then remove spreader tool from case.
11. Remove and tag selective shims located on each side of differential bearing bore to indicate side of carrier from which they were removed. Inspect shims for damage, bending or deep grooves. If damaged, replace during reassembly procedure.
12. Turn nose of carrier upward, hold end with companion flange holding tool No. T57T-4851-B, or equivalent, then remove pinion nut and washer from pinion assembly.
13. Using differential side bearing puller tool No. T77F-4220-B1, or equivalent, remove companion flange. Replace companion flange if it shows any sign of wear in seal contact area.
14. Remove drive pinion by tapping on drive pinion shaft using a rawhide or plastic hammer. Catch pinion to prevent damage to pinion teeth.

WARNING: Gear teeth may have sharp edges; use care when handling gear to prevent personal injury.

15. Using slide hammer tool No. T50T-100-A, or equivalent, remove drive pinion oil seal from carrier.
16. Remove outer pinion bearing cone and roller, oil slinger and collapsible spacer from carrier. Discard collapsible spacer.
17. Remove inner pinion bearing cup and baffle using a suitable pinion bearing cup remover and driver handle. Pass bearing cup remover and drive handle through outer bearing cup and place against inner bearing cup, then drive inner bearing cup out of bore. Use care not to damage oil baffle when removing inner bearing cup.
18. Remove oil baffle from inner bearing cup bore. Oil baffle is located between the inner bearing cup and carrier bore. If baffle is damaged during bearing cup removal, measure thickness and replace with baffle of equal thickness. If a baffle of equal thickness cannot be obtained, select adjustment shims and locate shims behind head of pinion to compensate for difference in thickness.
19. Turn nose of carrier downward and remove outer pinion bearing cup using a suitable pinion bearing cup remover and driver handle. Pass bearing cup remover and drive handle through inner bearing cup bore and place against outer bearing cup, then drive outer bearing cup out of bore.
20. Remove differential case bearings and shims from case. Position step plate tool No. D80L-630-4, or equivalent, under bearing, then install tool No. D81L-4220-A, or equivalent, and remove bearing. Turn case over and remove other bearing in the same manner.
21. Wire shims, bearing cup and cone together and identify from which side of differential case they were removed. If any shims are damaged, replace with new shims. It is recommended that bearings be replaced.
22. Place a few shop towels over a vise to prevent ring gear teeth from being nicked after it is free from case assembly. Remove ring gear bolts. Tap ring gear with a rawhide or plastic hammer to free it from case. Remove case and ring gear from vise.

NOTE: Always discard and replace ring gear bolts with new bolts upon assembly.

23. Remove bearing and oil slinger from drive pinion using universal bearing remover tool No. D81L-4220-A, or equivalent. For controlling drive pinion depth, an oil slinger with a selective thickness is used. If oil slinger is damaged, measure thickness and replace with a slinger of equal thickness.
24. Inspect all parts for damage and replace as required.