Differential Carrier

Differential Carrier











Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the axle assembly.
3. Remove the 10 differential housing cover bolts and the differential housing cover.
4. Remove the 2 differential bearing caps.
1 Remove the 4 differential bearing cap bolts.
2 Remove and identify the 2 differential bearing caps.





5. Install the special tool.





6. Install the axle assembly into the bench fixture.





7. Install the special tools.





8. CAUTION: Overspreading can damage the differential housing.

Spread the differential housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the differential carrier spreader screw.
3 Remove the dial indicator.





9. CAUTION: Use wood blocks to avoid damaging the differential housing.

Remove the differential assembly from the housing.
1 Position the wood blocks.
2 Push downward on the pry bars.
3 Remove the differential assembly.
4 Remove the special tool.





Installation
1. Install the special tools.
^ Position the clutch housing gauge needle in the differential carrier spreader adapter hole.





2. CAUTION: Overspreading can damage the differential housing.

Spread the differential housing to the specification.





3. Remove the dial indicator.





4. NOTE: Push the differential assembly downward to fully seat the differential bearing cups in the differential housing.

Install the differential bearing cups and the differential assembly in the differential housing.
1 Position the 2 differential bearing cups on the 2 differential bearings.
2 Lower the differential assembly in place.





5. CAUTION: Do not tighten the 4 differential bearing cap bolts to specification at this time.

Install the 2 differential bearing caps in their original positions.
1 Position the 2 differential bearing caps.
2 Install the 4 differential bearing cap bolts hand-tight.





6. Remove the spreader.
7. Tighten the 4 differential bearing cap bolts.
^ Tighten to 61 Nm (45 lb-ft).





8. Verify that the differential assembly rotates freely.
9. Check the ring gear backlash and remove the special tools.





10. Install the RH axle shaft.

11. NOTE: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.

NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.

NOTE: Allow the sealant to cure for one hour before filling the axle with lubricant.

Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.





12. Install the differential housing cover and the 10 differential housing cover bolts.
^ Tighten to 29 Nm (21 lb-ft).
13. Install the axle assembly.
14. Remove the fill plug and fill the axle with rear axle lubricant to 9.56 mm (0.38 inch) below the bottom of the filler hole.