Differential Case and Ring Gear - Conventional
Differential Case and Ring Gear - Conventional
Disassembly
1. Remove the differential carrier.
2. Remove and discard the 12 differential ring gear bolts.
3. Insert a punch in the differential ring gear bolt holes and drive the differential ring gear off.
4. NOTE: The anti-lock ring cannot be reused once removed.
If necessary, remove the anti-lock ring.
5. Remove the RH and LH differential bearings with the special tools.
6. Remove the differential pinion shaft lock bolt and the differential pinion shaft.
7. Rotate and remove the 2 differential pinion gears and the 2 differential pinion gear thrust washers.
8. Remove the 2 differential side gears and the 2 differential side gear thrust washers.
Assembly
1. Position the differential side gear thrust washers on the differential side gears.
^ Lubricate the differential side gear thrust washers and the differential side gear journals with axle lubricant.
2. Position the 2 differential side gears.
3. Assemble the 2 differential pinion gear thrust washers and the 2 differential pinion gears.
^ Lubricate the washers and gears with rear axle lubricant.
4. Engage the 2 differential pinion gears opposite the differential side gears.
5. Rotate the differential pinion gears to align the differential pinion shaft bore.
6. Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight.
7. Using the special tool, install the RH and LH differential bearings.
8. NOTE: If removed, press the new anti-lock ring on with the differential ring gear.
Install the differential ring gear on the differential case.
1 Position the ring gear on the differential case.
2 Hand start 3 new differential ring gear bolts to align the ring gear and the differential case.
3 Place the differential assembly in a press bed blocks with the ring gear teeth facing down.
4 Press the ring gear into place.
9. Install the 12 differential ring gear bolts.
^ Tighten to 150 Nm (111 lb-ft).
10. Place the differential assembly in the axle housing.
11. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.
Install a differential bearing shim on the left side.
12. NOTE: Apply pressure toward the left side to make sure the left differential bearing cup is seated.
Install the left differential bearing cap and loosely install the 2 differential bearing cap bolts.
13. Install progressively larger differential bearing shims on the right side until the largest differential bearing shim selected can be inserted by hand.
14. Install the right side differential bearing cap with the 2 bolts and tighten the 4 differential bearing cap bolts.
^ Tighten to 105 Nm (77 lb-ft).
15. Rotate the differential assembly to make sure it rotates freely.
16. NOTE: If ring gear backlash is within specification, go to Step 21.
NOTE: Specification shown is the maximum ring gear backlash allowable.
Using the special tools, measure ring gear backlash.
^ Turn the ring gear without turning the pinion gear and record the measurement.
17. NOTE: The differential bearing caps must be removed before differential bearing shims can be installed.
To increase ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim of the same thickness change.
^ If ring gear 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.
18. NOTE: The bearing caps must be removed before differential bearing shims can be installed.
To decrease ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim of the same thickness change.
19. Rotate the differential assembly several times to make sure the differential bearings are seated.
20. Using the special tools, recheck the ring gear backlash.
21. Remove the 4 differential bearing cap bolts and the 2 differential bearing caps.
22. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.
NOTE: To establish differential bearing preload, increase both left and right differential bearing shim sizes as shown. Make sure differential bearing shims are fully seated and the differential assembly turns freely.
Using the special tool, install the 2 differential bearing shims.
23. Install the 2 differential bearing caps and the 4 differential bearing cap bolts.
^ Tighten to 105 Nm (77 lb-ft).
24. Using the special tools, recheck the backlash.
25. Install the axle shafts.