Differential Case
Differential Case
Special Tools (1 Of 2):
Special Tools (2 Of 2):
Material:
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.
2. Remove the 10 bolts and the differential housing cover.
- Drain the lubricant from the rear axle.
3. Clean the gasket material from the differential housing cover and the differential housing.
4. Remove the axle shafts.
5. NOTE: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps.
Remove the 4 bolts and the 2 bearing caps.
6. NOTICE: Do not spread the differential housing more than specified or damage to the housing may occur.
Using the Differential Carrier Spreader and Dial Indicator Gauge with Holding Fixture, spread the differential housing.
7. NOTICE: It will be necessary to use large pry bars to remove the differential assembly from the differential housing. Do not damage the differential ring gear when carrying out this step.
NOTE: Mark or tag the differential bearing cups, indicating from which side they were removed.
Remove the differential assembly with the bearing cups.
- Inspect the differential bearing cups for deep scores, galling and spalling.
8. NOTE: Mark or tag the outboard spacers indicating from which side they were removed.
Remove the 2 outboard spacers.
- Inspect the spacers for nicks, bending or grooved conditions.
9. NOTE: Differential bearings shims are available in thicknesses of 0.762, 0.787, 0.813, 0.838, 0.864, 0.889 and 0.914 mm (0.030, 0.031, 0.032, 0.033, 0.034, 0.035 and 0.036 in).
NOTE: If damaged, install new differential bearing shims.
NOTE: Install new differential bearings and cups if removing the bearings from the differential case.
Using the Differential Carrier Bearing Collets, Bearing Tube Removal Screw, Bearing Tube Remover, Differential Carrier Bearing Step Plate and Differential Carrier Bearing Retaining Ring, remove the differential bearings.
- Tag the selective inboard spacers to identify the side from which they were removed.
10. NOTE: Use a vise with brass jaws or wood blocks.
Place the differential case in a vise.
11. NOTICE: Do not damage the anti-lock speed sensor ring when removing the differential ring gear.
NOTE: Always use new bolts upon reassembly.
Remove and discard 8 of the ring gear bolts. Leave 4 bolts loosely assembled, 90 degrees apart.
12. Tap each remaining bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove and discard the 4 bolts. Remove the differential ring gear.
13. If necessary, remove and discard the anti-lock speed sensor ring with a soft-faced hammer.
Installation
1. Install the outboard spacers in the side from which they were removed.
2. NOTE: Remove all nicks, burrs and dirt from the differential case hubs to allow the Dummy Bearing Set to rotate freely.
Place the Dummy Bearing Set on the differential case hubs and position the assembly into the differential housing.
3. NOTE: The rear axle uses a combination of differential bearing shims and selective outboard spacers to control differential case end play. The old outboard spacers provide a good starting point when setting end play. However, if additional shimming is necessary, beyond what the hardened differential bearing shims can provide, select and install different thickness outboard spacers.
Mount the Dummy Bearing Set and Dial Indicator Gauge with Holding Fixture as shown.
4. NOTE: Repeat this and the following step until the same readings appear on the Dial Indicator Gauge each time. This is the total differential bearing shim thickness necessary, less preload. The final calculation occurs later during assembly.
Force the differential case as far as possible toward the Dial Indicator Gauge. With force applied, set the Dial Indicator Gauge at 0. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.
5. After making sure the reading is repeatable, remove the differential case from the differential housing. Do not remove the Dummy Bearing Set from the differential case at this time.
6. Start 2 new 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 differential case align.
7. Press the anti-lock speed sensor on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.
8. Draw up the 12 new ring gear bolts alternately and evenly.
- Tighten to 298 Nm (220 lb-ft).
9. Place the differential assembly with the Dummy Bearing Set in the differential housing.
10. Install the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge. Locate the tip of the Clutch Housing Gauge on the flat surface of one of the bolts.
11. NOTE: Repeat this and the following step until the same readings appear on the Dial Indicator Gauge each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.
Force the differential case and ring gear away from the drive pinion. With force applied, set the Dial Indicator Gauge to 0.
12. Force the differential ring gear into mesh with the pinion to obtain a Dial Indicator Gauge reading. Record this measurement.
13. Remove the differential case from the differential housing.
14. Remove the Dummy Bearing Set from the differential case.
15. Place a shim of the thickness determined by the end play between the differential case and the ring gear/pinion on the ring gear side of the differential case. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
16. Using the Differential Carrier Bearing Installer, install the new differential bearing on the differential ring gear side of the differential case.
17. Determine the correct shim thickness and place the shim on the differential case hub on the drive pinion side.
- To determine the correct shim thickness, first subtract the thickness of the ring gear side differential case hub shim from the total differential case end play reading recorded earlier. Then, add 0.25 mm (0.010 in) to this amount. This result is the correct thickness of shim to place on the pinion side differential hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
18. Using the Differential Carrier Bearing Installer, install the differential bearing.
1. Place the Differential Carrier Bearing Step Plate on the differential bearing to protect it during the installation of the opposite bearing.
2. Using the Differential Carrier Bearing Installer, drive the differential bearing onto the hub.
19. Assemble the differential bearing cups to the differential bearings.
20. NOTICE: Do not spread the differential housing more than specified or damage to the housing may occur.
NOTICE: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly or damage to the component may occur.
Using the Differential Carrier Spreader and Dial Indicator Gauge with Holding Fixture, spread the differential housing to specifications and position the differential assembly.
- Use a rawhide hammer to seat the differential in the differential housing.
21. NOTE: Match the mating letters as noted during disassembly.
Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.
- Tighten to 108 Nm (80 lb-ft).
22. Carry out the Tooth Contact Pattern Check to verify that the final pinion position is correct. For additional information, refer to Differential Assembly and/or Axle Shaft Assembly and/or Drive/Propeller Shafts, Bearings and Joints.
23. Install the axle shafts. For additional information, refer to Differential Assembly and/or Axle Shaft Assembly.
24. NOTE: Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.
Apply a continuous bead of sealant to the differential housing cover as shown.
25. Install the differential housing cover and the 10 bolts.
- Tighten alternately and evenly to 45 Nm (33 lb-ft).
26. NOTE: If possible, allow an hour cure time before filling the axle with the correct amount of specified lubricant.
Fill the axle with the specified type and amount of lubricant.