Differential Case and Ring Gear - Traction-Lok(R)

Differential Case and Ring Gear - Traction-Lok(R)

Disassembly

1. Remove the differential carrier. For additional information, refer to Differential Carrier Differential Carrier.

2. Index-mark the differential case.

1. Index-mark the differential case halves.

2. Index-mark the differential pinion shafts and corresponding ramps.





3. NOTE: Whenever removing the differential ring gear bolts, always install new Grade 9 differential ring gear bolts.

Remove and discard 8 of the differential ring gear bolts. Leave 4 differential ring gear bolts loosely assembled, 90 degrees apart.





4. Tap each differential ring gear bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove and discard the 4 differential ring gear bolts. Remove the differential ring gear.





5. NOTE: An axle shaft held in a vise, with the shaft splines extending not more than 3 inches above the vise jaws, makes an excellent holding fixture for the differential case.

Loosen, but do not remove, the 8 bolts.





6. Place the differential assembly on a bench.

7. Remove the bolts and the case top half.





8. Remove the differential side gear, rear axle disc and plate kit, differential pinion gears and the differential pinion shafts. Keep these parts in order for correct installation by placing them aside with the top half of the differential case.





9. Remove the side gear and the rear axle disc and plate kit from the flange half of the differential case. Keep these parts in order by placing them on the pinion flange as shown.





10. Inspect the following components:
- The clutch plates and clutch discs for cracks, excessive wear and distortion. Always install an entirely new rear axle disc and plate kit on both sides if discarding one or more of the clutch plates or clutch discs.

- The differential pinion shafts and the ramp surfaces on the differential case for excessive wear or pitting.

- The differential side gear and differential pinion gear teeth.

Assembly

1. NOTE: After assembly, make sure that the side gear splines engage the clutch pack splines and the differential side gear is fully seated.

Assemble and install the side gear, the rear axle disc and plate kit in the flange half of the differential case. Assemble and install the side gear, the rear axle disc and plate kit in the top half of the differential case.











2. NOTE: Align the index marks made during disassembly.

Place the differential pinion shaft and differential pinion gears in the case top half.





3. NOTE: Align the index marks made during disassembly.

Install the other differential pinion shaft and differential pinion gears in the flange half of the differential case.





4. NOTE: Align the match marks made during disassembly.

Assemble the differential case.

- Place the top half of the differential case onto the flange half of the differential case assembly.

- NOTE: The bolts must be clean and dry.

Install the bolts. Turn each one in a few threads.

- Tighten the bolts evenly and alternately.
- Tighten to 129 Nm (95 lb-ft).





5. NOTE: If removed, install the anti-lock speed sensor ring.

Start 2 new ring gear bolts through the differential case flange, the anti-lock sensor ring and into the differential ring gear to make sure the differential ring gear and the differential case align.





6. Press the anti-lock speed sensor ring and differential ring gear on the differential carrier. The differential carrier flange acts as a pilot for the anti-lock speed sensor ring.





7. Install the 10 new remaining ring gear bolts alternately and evenly.
- Tighten to 298 Nm (220 lb-ft).





8. Install the differential carrier. For additional information, refer to Differential Carrier Differential Carrier.