Disassembly
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Special Tool(s)
Disassembly
All Axles
1. Remove the axle assembly from the vehicle.
2. Remove the four bolts retaining the torque arm to the rear axle housing.
3. Drain the rear axle lubricant and remove the rear axle cover.
4. Using the special tools, mount the differential housing to a work bench.
5. Using the special tool, measure and record the differential ring gear backlash between teeth in four equally spaced places around the ring gear.
^ Remove the dial indicator.
6. CAUTION: Mark the position and location of the differential bearing caps as the arrows may not be visible. Always install the differential bearing caps in their identical location and position.
Remove the differential bearing caps.
7. CAUTION: Use wood blocks to avoid damaging the differential housing.
NOTE: Tag the bearing caps and shims for location as removed.
Remove the differential assembly.
1 Position wood blocks at the top and bottom of the differential case.
2 Pry the differential assembly and the differential bearing shims out of the differential housing.
8. Record the torque necessary to maintain rotation of the drive pinion gear through several revolutions prior to removing the drive pinion
9. CAUTION: After removing the drive pinion nut, discard it. Use a new nut for installation.
Using the special tool, remove the drive pinion nut.
10. Index-mark the drive pinion flange and drive pinion gear stem to maintain initial balance during installation.
11. Remove the drive pinion flange and the pinion seal.
12. Remove the drive pinion shaft oil slinger.
13. Using the special tool and a soft-faced hammer, drive the drive pinion gear out of the front pinion bearing and remove it through the rear of the differential housing.
14. Remove and discard the drive pinion collapsible spacer.
15. Using the special tool and a suitable press, remove the drive pinion bearing.
16. NOTE: Using a micrometer, measure the drive pinion bearing adjustment shim thickness. Use this measurement as a reference to compare to the shim gauge reading taken prior to installing the pinion bearing.
Remove the drive pinion bearing adjustment shim.
17. Using the special tools, remove the outer drive pinion bearing cup, if necessary.
18. Using the special tools, remove the inner drive pinion bearing cup.
19. If the differential ring gear backlash between teeth measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to Final disassembly. If the differential ring gear backlash between teeth measurement exceeds the specification, the cause may be a warped differential ring gear, a damaged differential case, or loss of differential bearing preload. Proceed to Excessive differential ring gear backlash between teeth to verify the cause of the excessive runout.
Excessive differential ring gear backlash between teeth
20. Remove the ring gear bolts.
21. CAUTION: Do not damage the bolt hole threads.
Insert a punch in the bolt holes and drive off the differential ring gear.
22. NOTE: Visually inspect the differential carrier bearings and cups for discoloration or other signs of bearing failure.
NOTE: Install the differential bearing cups and shims in the same locations they were in before disassembly.
Install the differential case. Rotate the differential case to seat the differential bearings.
23. Using the special tool, measure the differential case flange runout.
1 Rotate the differential case to make sure the differential bearings are seated.
2 Position the special tool.
^ If the runout does not exceed the specification, the cause of the original excessive runout is the differential ring gear. Remove the differential case. Discard the differential ring gear and the drive pinion gear. Proceed to Final disassembly.
^ If the runout exceeds the specification, the differential ring gear is true and the concern is due to either differential case/differential bearing damage. Remove the differential case. Discard the differential bearings/differential case. Proceed to Final disassembly.
- Remove the special tool.
Final Disassembly, Differential Case and Ring Gear-Traction-Lok
24. Remove the differential ring gear bolts
25. CAUTION: Do not damage the ring gear bolt hole threads.
Insert a punch in the bolt holes and drive the differential ring gear off the differential case.
26. NOTE: The differential bearings do not need to be removed to overhaul the Traction-Lok differential. If bearing removal is required, use special tool 205-D072 and special tool 205-D019 for the differential case bearings.
Remove the differential pinion shaft lock bolt and remove the differential pinion shaft.
27. Install the special tool in a suitable vise.
28. Install the differential case on the tool.
29. NOTE: Apply a small amount of grease to He centering hole of the special tool.
Install the special tool in the bottom side gear bore.
30. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex nut until contact is made with the step plate.
31. NOTE: The dowel bar is used to keep the nut from turning when the forcing screw is tightened.
Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears.
32. Insert the special tool in the pinion shaft bore and turn the differential case to move the differential pin gears and thrust washers to the differential case opening.
33. Remove the differential pinion gears and differential pinion gear thrust washers.
34. Remove the differential side gears and differential clutch packs. Tag the gears, clutch packs and shims for location.
35. CAUTION: When separating the clutch plates and clutch discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence.
CAUTION: Do not use acids or solvents to clean the differential clutch components. Use a clean, lint-free cloth only.
Separate the differential clutch packs for cleaning and inspection.
Final Disassembly, Differential Case and Ring Gear-Conventional
36. Remove the differential ring gear bolts.
37. CAUTION: Do not damage the ring gear bolt hole threads.
Insert a punch in the bolt holes and drive off the differential ring gear.
38. Using the special tools, remove the differential bearing.
^ Repeat for the other side.