Differential Case
Differential Case
Special Tool(s)
Material
Removal
1. Remove the axle shafts.
2. Wipe the lubricant from the internal working parts, and visually inspect the parts for wear or damage.
3. Rotate the differential case to see if there is any roughness to indicate damaged bearings or gears.
4. Position the special tool, and record ring gear backlash at four evenly spaced sections of the ring gear.
5. CAUTION: Mark the position of the bearing caps because the arrows may not be visible. The bearing caps must be installed in their identical locations and positions.
Loosen the differential case.
1. Remove the bolts.
2. Remove the bearing caps.
6. To simplify removal, fabricate two differential case retaining straps from metal stock as shown.
7. WARNING: Be careful to not allow the differential case to fall.
CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage.
Use the pry bar and the wood block to remove the differential case from the rear axle housing.
8. Remove the bolts.
9. CAUTION: Care should be taken to not damage the ring gear bolt hole thread.
NOTE: The anti-lock speed sensor ring cannot be reused once removed.
Insert a punch in the bolt holes. Drive off the ring gear and, if necessary, the anti-lock speed sensor ring.
10. Install the differential case.
1. Position the differential case assembly, including bearing cups and shims, in the carrier.
2. Install the differential bearing caps.
3. Install the differential bearing cap bolts.
11. Position the special tool.
1. Rotate the differential case to make sure the differential bearings are correctly seated.
2. Install the special tool.
12. NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, install a new differential case and the differential bearings.
Measure the differential case runout without the ring gear.
1. Rotate the differential case.
2. Check and note the differential case runout.
13. Using the special tools, remove the differential case from the rear axle housing, and remove the differential bearings.
14. Using the special tool, install the new differential bearings on the differential case.
15. Measure the differential case runout without the ring gear.
^ Check the case runout again with the new differential bearings. If the runout is within specification, use the new differential bearings for assembly. If the runout is still excessive, a new differential case must be installed.
Installation
All vehicles
1. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.
Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case.
2. Install the bolts.
^ Apply sealer to the ring gear bolts.
3. With pinion depth set and the pinion installed, place the differential case in the rear axle housing.
4. Install a shim on the left side, of the specification shown.
5. CAUTION: The bearing caps must be installed in their original locations and positions.
NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.
Install the left bearing cap and loosely install the bearing cap bolts.
6. Install progressively larger shims on the right side until the largest shim selected can be inserted by hand.
7. Install the right side bearing cap and tighten the bolts.
8. Rotate the differential case to make sure it rotates freely.
Measure backlash
9. Using the special tool, measure ring gear backlash.
^ If the backlash is within specification, go to Backlash Within Specification in this procedure. The specification shown in the illustration is the total allowable range.
^ If a zero backlash condition occurs, go to Zero Backlash in this procedure.
^ If the backlash is not within specification, go to Backlash Not Within Specification in this procedure.
Zero backlash
10. If a zero backlash condition occurs, add a 0.50-mm (0.020-inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Go to Measure Backlash in this procedure.
Backlash not within specification
11. To increase or decrease backlash, remove the bearing caps, and install a thicker shim and a thinner shim as shown.
^ If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
12. Install the bearing caps and bearing cap bolts.
13. Rotate the differential several times to make sure the differential bearings are correctly seated.
14. Using the special tool, recheck the backlash.
^ If backlash is within specification, go to Backlash Within Specification in this procedure. If not, go to Measure Backlash in this procedure.
^ The specification shown in the illustration is the total allowable range.
Backlash within specification
15. Remove the bearing caps and bolts.
^ To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
^ Using the special tool, make sure the differential bearing shims are fully seated and the assembly turns freely.
16. Install the bearing caps and bearing cap bolts.
17. Use the special tool to verify the backlash.
^ The specification shown in the illustration is the total allowable range.
18. Install the axle shafts.