Differential Case and Ring Gear -Conventional
Differential Case and Ring Gear -ConventionalSpecial Tools:
Special Tool(s)
Materials
Disassembly
1. NOTE: Differential bearing shims are available in thicknesses of 0.762, 0.787, 0.813, 0.838, 0.864, 0.889, and 0.914 mm (0.03, 0.030, 0.031, 0.032, 0.033, 0.034, 0.035, and 0.036 inch).
NOTE: If differential bearing shims are damaged, install new ones.
NOTE: Install new differential bearings whenever they are removed from the rear axle differential carrier.
Using the special tools, remove the differential bearings.
^ Wire the differential bearing shims, differential bearing cup, differential bearing and outboard selective spacer together. Note from which side they were removed (ring gear side or opposite side).
2. NOTE: Use a vise with brass jaws or wood blocks.
Place the differential case in a vise.
3. CAUTION: Do not damage the anti-lock speed sensor ring when removing the ring gear. If the anti-lock speed sensor ring is removed, a new one must be installed.
NOTE: Whenever removing the ring gear bolts, always install new bolts upon assembly. Use Grade 9 bolts for service replacement for all Dana rear axles.
Remove the bolts on the ring gear. Leave four bolts loosely assembled, 90 degrees apart.
4. Tap each bolt head alternately with a rawhide or plastic hammer to loosen the ring gear. Remove the bolts and the ring gear.
5. If required, remove the anti-lock speed sensor ring with a soft-faced hammer. Discard the anti-lock speed sensor ring.
6. NOTE: Use a vise with brass jaws or wood blocks.
Place the differential case in a vise. Using a small drift, drive out the differential pinion shaft lock pin that secures the differential pinion shaft.
7. Using a drift, remove the differential pinion shaft.
8. To remove the differential side gears and the differential pinion gears, rotate the differential side gears. The differential pinion gears will turn to the opening of the differential case.
9. Remove the differential pinion gears and the differential pinion thrust washers behind the differential pinion gears.
10. Lift out the differential side gears and the differential side gear thrust washers.
Assembly
1. NOTE: Use a vise with brass jaws or wood blocks.
Place the differential case in a vise.
2. Apply grease to the new differential side gear thrust washers and to the thrust face of the new differential side gears.
3. Apply grease to the new differential pinion thrust washers and the new differential pinion gears.
4. Lubricate the differential side gears and differential pinion gears.
^ For Model 60 axles, use High Performance Rear Axle Lubricant.
^ For Model 70/80 axles, use Premium Rear Axle Lubricant.
5. Assemble both differential side gears and differential side gear thrust washers. Hold the assembly in place by hand, then assemble the differential pinion gears and differential side gear thrust washers to hold the differential side gears in place.
6. NOTE: Rotate the differential side gears until the holes of the differential side gear thrust washers and the differential pinion gears line up with the holes of the differential case. If the differential pinion gears cannot be rotated by hand, install one of the axle shafts into the spline of the differential side gear and use a pipe wrench to turn the axle shaft.
Using a drift, line up the holes with those of the differential case.
7. Assemble the differential pinion shaft and drive on the differential pinion shaft to remove the drift. Align the lock pin hole of the differential pinion shaft with the lock pin hole of the differential case.
8. Assemble the differential pinion shaft lock pin. Peen the metal of the differential case over the differential pinion shaft lock pin in two places, 180 degrees apart, to lock in place. Note the location of the slot in the differential pinion shaft lock pin and peen 90 degrees away.
9. Apply threadlock to the new ring gear bolts.
10. NOTE: The tab on the anti-lock speed sensor ring must be aligned with the slot in the differential case.
Align the tab in the anti-lock speed sensor ring with the slot in the differential case. Start the two ring gear bolts through the differential case flange into the ring gear to make sure the differential case and the ring gear bolt hole align.
11. Press the anti-lock speed sensor ring on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.
12. Apply threadlock to the new ring gear bolts.
13. Install and tighten the Grade 9 ring gear bolts alternately and evenly.
14. NOTE: For additional information, refer to Differential Case and Pinion Set Up.
Install the differential bearings.