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

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








Disassembly

1. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Fire Suppression System. Failure to follow the instructions may result in serious personal injury.

Remove the differential assembly from the differential housing.
2. Remove the 10 differential ring gear bolts.





3. NOTE: Do not damage the bolt hole threads.

Insert a punch in the bolt holes and drive off the differential ring gear.





4. Using the special tools, remove the differential bearings.





5. Remove the differential pinion shaft bolt and discard. Remove the differential pinion shaft.





6. CAUTION: Due to the spring tension, use care when removing the differential clutch spring. Failure to follow this instruction may result in component damage.

Remove the differential clutch spring.





7. Remove the differential gears.
1. Remove the 2 differential pinion gears.
2. Remove the 2 differential side gears.
3. Remove the 2 differential pinion thrust washers.





8. CAUTION: Keep the differential clutch packs in order. Do not mix them. Always reassemble them in the same sequence or component damage may occur.

Separate the differential clutch packs and shims from the differential side gears and tag them "right" and "left."
^ Clean and inspect the remaining differential components for wear and damage and install new parts as necessary.





9. CAUTION: Do not use acids or solvents when cleaning the differential clutch packs. Wipe the components only with a clean, lint-free cloth or component damage may occur.

Clean and inspect the differential clutch packs for wear and damage and install new parts as necessary.

Assembly

1. CAUTION: Use 118 ml (4 oz) of the friction modifier in the axle or component damage may occur.

Using the modifier, lubricate each steel clutch plate and soak all the friction plates for no less than 15 minutes.





2. Assemble the differential clutch packs (without the shims) on their respective differential side gear.





3. Install the differential side gear assemblies in the differential case.





4. Install the differential pinion gear and differential pinion thrust washer assemblies in the differential case.





5. Using a soft-faced hammer, install the differential clutch spring.





6. Install the differential pinion shaft and install a new bolt finger-tight.





7. Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
^ If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary.





8. Using the special tool, install the differential bearings.





9. Position the differential ring gear and the differential case. Align the bolt holes by starting 2 bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.





10. NOTE: Clean bolt threads to make sure the bolts are free of foreign material.

Apply stud and bearing mount to the differential ring gear bolt threads and install the bolts.
^ Install new bolts.
^ Tighten to 114 Nm (84 lb-ft).





11. Install the differential assembly.

12. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System. Failure to follow these instructions may result in serious personal injury.

If equipped with fire suppression system, repower the system.