Differential Case
Differential Case
Removal and Installation
Removal
1. Remove the axle shafts.
2. NOTE: Inspect the removed lubricant for metallic particles which indicate wear or damage.
Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.
3. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears.
4. Using the special tool, measure and record the differential ring gear backlash between teeth at 4 places around the ring gear.
^ Remove the special tool.
5. NOTE: Mark the position of the bearing caps as the arrows may not be visible. The bearing caps must be installed in their original locations and positions.
Remove the 4 bearing cap bolts and the 2 bearing caps.
6. NOTE: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage.
Use pry bars and wood blocks to remove the differential case from the axle housing.
7. If the differential ring gear backlash measurement between teeth, taken at the beginning of this procedure, did not exceed the specification, proceed to Final disassembly in this procedure. If the differential ring gear backlash measurement between teeth, taken at the beginning of this procedure, exceeded the specification, the cause may be a warped differential ring gear, a damaged differential case, or loss of differential bearing preload. Proceed to Excessive differential ring gear backlash between teeth in this procedure to verify the cause of the excessive backlash.
Excessive differential ring gear backlash between teeth
8. Remove and discard the 10 ring gear bolts.
9. NOTE: Do not damage the bolt hole threads.
Insert a punch in the bolt holes and drive off the differential ring gear.
10. Install the differential case, differential bearings, cups and shims in their original location. Rotate the differential case to seat the differential bearings.
11. Install the special tool. Measure the differential case flange runout.
^ If the runout does not exceed the specification, the cause of the original excessive backlash between teeth concern is the differential ring gear. Remove the differential case. Discard the differential ring gear and the drive pinion gear. Proceed to Final disassembly in this procedure.
^ If the runout exceeds the specification, the differential ring gear is true and the concern is due to either differential case/differential bearing damage. Remove the differential case. Discard the differential bearings/differential case. Proceed to Final disassembly in this procedure.
- Remove the special tool.
Final disassembly
12. If not done previously, remove and discard the 10 ring gear bolts.
13. NOTE: Do not damage the bolt hole threads.
If not done previously, insert a punch in the bolt holes and drive off the differential ring gear.
14. Using the special tools, remove the differential bearing.
^ Repeat for the other side.
15. The TORSEN(R) differential is a non-serviceable component and should not be disassembled. If the differential is damaged, a new differential must be installed.
Initial assembly
16. Install the differential ring gear.
^ Place the differential ring gear and the anti-lock speed sensor ring on the differential case.
^ Hand start 2 new bolts to align the holes in the differential ring gear and the differential case.
^ Place the differential case and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
^ Press the differential ring gear into place.
17. Install the 10 new ring gear bolts.
^ Tighten to 105 Nm (77 lb-ft).
18. Press the left and right differential bearing on the differential case.
19. Place the differential assembly in the differential housing.
20. Install a differential bearing shim of the size shown on the left side of the differential.
21. NOTE: Always install the bearing caps in their original locations and positions.
NOTE: Apply pressure toward the left side of the differential to make sure the left differential bearing cup seats correctly.
Install the left differential bearing cap and loosely install the 2 bolts.
22. Install progressively thicker differential bearing shims on the right side until the thickest shim possible is installed by hand.
23. Install the right side bearing cap and tighten the 2 left and 2 right side bolts.
^ Tighten to 112 Nm (83 lb-ft).
24. Rotate the differential case to make sure the differential turns freely.
Measuring backlash
25. Using the special tools, measure the differential ring gear backlash at 4 equally spaced points.
^ If the backlash is not within the specifications, refer to Backlash not within specification in this procedure.
^ If a zero backlash condition occurs, refer to Zero backlash in this procedure.
^ If the backlash is within specification, refer to Backlash within specification in this procedure.
Backlash not within specification
26. To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the following tables when adjusting the backlash. When the backlash is within specification, proceed to Final assembly in this procedure.
Zero backlash
27. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow the backlash indication. Measure the backlash. Refer to Measuring backlash in this procedure.
Backlash within specification
28. Remove the 4 bolts and 2 bearing caps.
29. To establish differential bearing preload, increase both the left and right differential bearing shim sizes by the specification shown.
30. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
31. Install the 2 bearing caps and 4 bolts.
^ Tighten to 112 Nm (83 lb-ft).
32. Using the special tools, recheck the backlash.
33. Install the axle shafts.