Differential Case and Ring Gear
Differential Case and Ring Gear
Special Tool(s)
Disassembly
1. Mount the carrier housing in a suitable repair stand.
2. CAUTION: If reusing the differential ring gear and pinion, measure and record the backlash before disassembly. Assembling the differential ring gear and pinion to the recorded backlash will match the established wear patterns. Hand-rolled patterns will cover less area than the established patterns.
Measure and record the differential ring gear and pinion backlash.
^ Check the backlash in four equally spaced positions around the differential ring gear.
^ The tooth contact pattern can move only by adjusting backlash. The tooth contact pattern can move only in the direction of heel-to-toe and toe-to-heel. Depth of the tooth contact pattern is not adjustable.
3. Remove the rear anti-lock brake sensor.
4. Remove the adjusting ring cotter pins.
5. Loosen, but do not remove, the six bearing cap bolts.
6. Relieve the bearing preload.
^ Loosen each differential bearing adjusting ring.
7. Remove the bolts, bearing caps and adjusting rings.
8. Carefully lift the differential subassembly out of the carrier.
9. Inspect the bearing surfaces for pitting, wear and overheating.
10. Using the special tools, remove the differential side bearings if worn or damaged.
11. Remove the twelve ring gear bolts.
12. Place the differential assembly in a suitable press supported on the ring gear.
13. WARNING: The differential case will fall after separation. Support the case so it will not result in damage to the component or equipment. Failure to follow these instructions can result in personal injury.
CAUTION: It should not require more than 3 tons of press load to separate the ring gear from the differential case.
CAUTION: Do not bend the differential pinion cross shaft.
The press arbor will push on the differential pinion cross shaft to separate the ring gear half of the differential from the cross shaft half of the assembly.
14. CAUTION: Discard the anti-lock speed sensor ring if separating it from the ring gear side case half.
If necessary, remove the anti-lock speed sensor ring.
15. CAUTION: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum-based cleaning solvents.
CAUTION: Use soft, clean, lintless towels to dry the components.
CAUTION: Never spin-dry bearings with compressed air. This will damage the mating surfaces due to a lack of lubrication.
CAUTION: 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.
NOTE: For Truetrac differentials submerge the entire differential assembly in a suitable solvent to wash away contaminants from within the housing.
Clean and dry the components.
16. The Truetrac differential assembly is non-repairable. Discard the entire assembly if it is worn or damaged.
17. With a conventional differential, lift out the side gear.
18. Remove the differential pinion cross shaft lock pin.
19. CAUTION: Discard all gears in sets if one or more sustains wear or damage.
Remove the pinion cross shaft.
20. Remove the inner side gear and thrust washer.
21. Refer to Drive Pinion if disassembly is necessary.
Assembly
1. If removed, install a new anti-lock speed sensor ring with a dead blow hammer.
2. Press the anti-lock speed sensor ring on the case flange.
3. Install the inner side gear thrust washer and inner side gear.
4. Align the pinion gear cross shaft with the pin hole vertical position.
5. NOTE: Lightly lubricate all of the mating surfaces with clean axle lubricant. This will aid in assembly and provide initial lubrication.
Install the first pinion gear thrust washer and pinion gear on the pinion cross shaft.
6. Install the second pinion gear and pinion gear thrust washer on the differential cross shaft.
7. Install the differential cross shaft lock pin.
8. NOTE: There is no thrust washer in this location.
Install the outer side gear.
9. Align the ring gear and the differential case bolt holes. Install the bolts in the holes finger tight.
10. Using the special tool and a shop press, press the differential assembly half on the ring gear half.
11. Install the ring gear bolts.
12. Using the special tools, install the ring gear side carrier bearing.
13. Using the special tools, install the differential side carrier bearing.
14. Carefully position the differential assembly into the carrier housing.
15. CAUTION: The bearing cups must seat on the differential side bearings.
CAUTION: Align the match marks.
CAUTION: The bolt threads must be clean.
Install the differential bearing caps.
1 Position the bearing cap onto the leg.
2 Apply Threadlock 262 to the bolt threads, and install the bolts.
^ Tighten the bolts enough to eliminate visible space between the bearing cap and leg. Do not tighten the bolts to the -appropriate torque at this time.
16. CAUTION: Align the differential assembly within the bearing bores before applying preload or damage to the bearings will result.
Install the differential bearing adjusting rings.
^ Tighten both adjusting rings until there is zero end play, and some backlash between the differential ring gear and pinion. Make sure the adjusting ring tooth aligns so that installation of the adjusting ring cotter pin is possible.
17. Set the backlash at zero.
^ NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring cotter pin is possible.
Loosen the adjusting ring on the tooth side of the differential ring gear one tooth, and tighten the opposite adjusting ring one tooth. Repeat this process until backlash is at zero.
18. Set the backlash and the bearing preload to specifications.
^ With a new matched set installed, set the backlash to the specification.
^ With the original matched set installed, set the backlash to the specification recorded prior to disassembly.
^ NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring cotter pin is possible.
Tighten the adjusting ring on the tooth side of the differential ring gear until backlash is within specifications.
19. Check the differential ring gear and pinion backlash in four equally spaced positions around the differential ring gear.
^ The acceptable backlash tolerance is ±0.0508 mm (0.002 inch) from the backlash specification.
^ If the backlash tolerance varies more than 0.080 mm (0.003 inch) between the four positions, remove the differential and determine the cause.
20. Tighten the bolts.
^ Check the differential ring gear and pinion backlash, as described in the previous step, after tightening the bolts.
21. Install the adjusting ring cotter pins.
22. Install the rear anti-lock brake sensor, if equipped.
23. Install the carrier.