Dana 35-Front Drive Axle/Differential
Differential Case
Disassembly
1. Remove the differential carrier.
2. Remove the differential ring gear.
1 Remove and discard the 10 bolts.
2 Using a drift that will bottom-out in the bolt holes, separate the differential ring gear from the differential case.
3. Drive out the differential pinion shaft roll pin.
4. Remove the differential pinion shaft.
5. NOTE: The upper differential side gear may fall out of the case bore after removing the differential pinion gears.
Rotate the 2 differential pinion gears to the differential case window and remove them and the 2 differential pinion thrust washers.
6. Remove the 2 differential side gears and 2 thrust washers.
7. Using the special tools, remove the differential bearing.
8. Assemble the special tool.
9. Position the special tool on the differential bearing.
10. Using the special tool, remove the differential bearing.
^ Repeat the procedure for the other bearing.
Assembly
1. Lubricate the differential side gear thrust washers and the differential side gears, and assemble them.
2. Position the differential side gear and thrust washer assemblies in the differential case.
3. Lubricate the differential pinion thrust washers and the differential pinion gears, and assemble them.
4. Engage the differential pinion gears between the differential side gears.
5. Rotate the differential pinion gears and align them with the differential pinion shaft bore.
6. Insert the differential pinion shaft.
7. Install the differential pinion shaft roll pin.
8. NOTE: Do not reuse the original bolts.
Using a suitable press, install the differential ring gear.
1 Position the differential ring gear and the differential case. Start 3 new bolts to align the holes in the ring gear and the differential case.
2 Using a suitable press, install the differential ring gear.
9. Install the remaining 7 new differential ring gear bolts.
^ Tighten to 122 Nm (90 lb-ft).
10. Install the differential bearing shims and the differential bearings.