Differential Carrier

Differential Carrier














Removal

NOTICE: Do not use heat when disassembling a drive axle. To do so will destroy heat treat properties and weaken or distort axle components and damage to the components may result.

All vehicles

1. Set the parking brake.

2. Chock the wheels.

3. Remove the bottom 2 carrier bolts and drain the assembly.
- Drain the axle lubricant into a suitable container.





4. Disconnect the rear wheel speed sensor electrical connector.





Vehicles with split pin yoke

5. Index-mark the driveshaft and pinion flange for reassembly.





6. Remove and discard the 4 driveshaft bolts and 2 U-joint straps.





Vehicles with circular flange

7. Index-mark the driveshaft and pinion flange. Remove and discard the 4 bolts.

All vehicles

8. NOTE: Do not allow the driveshaft to hang unsupported.

Position the driveshaft aside.

9. Loosen the pinion hex nut if drive pinion disassembly is necessary.





10. NOTICE: Do not strike the axle shaft flange directly with a steel hammer or sledge. This will crack and splinter the flange and damage the component.

NOTICE: Do not pry or chisel the axle shaft flange away from the hub. This will damage the sealing surface.

Remove the axle shafts. For additional information, refer to Differential Assembly and/or Axle Shaft Assembly.

11. Remove all but the 2 top differential carrier housing bolts, noting the length and position of each bolt.
- Discard the 10 differential carrier housing bolts.





12. WARNING: Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious personal injury.

Remove the carrier from the axle housing in the following sequence.

1. Position a suitable jack under the carrier.

2. Remove and discard the 2 remaining top differential carrier housing bolts.

3. Use the slots to separate the carrier approximately 25.4-50.8 mm (1-2 in) from the axle housing.

4. Secure the carrier to a suitable jack and remove the carrier from the axle housing.

13. NOTICE: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum-based cleaning solvent.

NOTE: Use only soft, clean, lintless towels to dry the components.

NOTE: After drying, lightly coat the parts with rust inhibitor or clean lubricant to prevent damage from corrosion. Wrap all parts that are going to be in storage for a prolonged period in wax paper.

Clean and dry the components as necessary.

14. Inspect the gear set for pitting, scoring, wear or damage. Install new components as necessary.





15. Inspect the splines for wear, cracking or distortion from twisting.





16. Inspect the axle flange O-ring.





17. Clean the axle housing interior, the axle and carrier housing sealing surfaces and the carrier mounting bolt hole threads. Inspect the housing for stripped and damaged threads and bending fatigue. Repair or install new components as necessary.





18. If carrier disassembly is necessary, refer to Differential Case and Ring Gear Differential Case and Ring Gear.

Installation

All vehicles

1. NOTE: The gasket material should cure for one hour before filling the axle with lubricant.

Apply a continuous bead of gasket maker onto the axle housing mounting flange and around each bolt hole as shown.





2. Thread 2 studs into the axle housing. This will eliminate rotation of the carrier assembly after it makes contact with the gasket material.





3. WARNING: Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious personal injury.

Position the carrier into the axle housing, using the 2 studs to align the carrier and housing.





4. NOTE: Make sure the bolt threads are clean.

NOTE: Remove the 2 alignment studs only after installing several of the bolts.

Install 14 new differential carrier housing bolts.

- Tighten alternately and evenly to 203 Nm (150 lb-ft).





5. Install the axle shafts. For additional information, refer to Differential Assembly and/or Axle Shaft Assembly.

Vehicles with split pin yoke

6. Position the driveshaft. Install the 2 U-joint straps and 4 new bolts.
- Tighten the 62 Nm (46 lb-ft).





Vehicles with circular flange

7. Position the driveshaft. Install the 4 new bolts.
- Tighten to 100 Nm (74 lb-ft).

All vehicles

8. Connect the rear wheel speed sensor electrical connector.





9. Remove the fill plug.





10. NOTE: A lubricant level close enough to the bottom of the fill hole to be seen or touched is not sufficient. The lubricant must be level with the fill hole.

Fill the axle with axle lubricant until the lubricant is level with the fill hole.

11. Clean and install the fill plug.
- Tighten to 68 Nm (50 lb-ft).





12. Remove the wheel chocks.

13. Release the parking brake.