Dana 35-Front Drive Axle/Differential

Differential Carrier








Removal

NOTE: Many components and surfaces in the axle are precision machined. Careful handling during disassembly, cleaning, inspection and assembly will prevent unnecessary damage to machined surfaces.

1. Remove the front drive axle assembly from the vehicle.
^ If equipped, remove the front axle damper from the axle-to-frame bracket.

2. Attach the axle assembly to the special tool.





3. Remove the differential housing cover.
1 Remove the 10 bolts.
2 Remove the differential housing cover.





4. Drain the axle lubricant from the differential housing.
5. Using a jerking motion, remove the axle shaft.





6. CAUTION: The matched numbers or letters stamped on both of the differential bearing caps and the differential housing must correspond during assembly or damage to the component may occur.

Remove the differential bearing caps.
1 Remove the 4 bolts.
2 Remove the 2 differential bearing caps.





7. NOTE: The special tool bolts have a minimum thread engagement as specified.

Install the special tool.





8. Install the special tools.
^ Position the Clutch Housing Gauge needle in the Differential Carrier Spreader hole.





9. CAUTION: Overspreading may damage the differential housing.

Spread the differential housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the Differential Carrier Spreader screw to spread the differential housing to the specification.
3 Remove the Dial Indicator with Holding Fixture and the Clutch Housing Gauge.





10. CAUTION: Use wood blocks to avoid damaging the differential housing.

Remove the differential assembly from the differential housing.
1 Position the wood blocks.
2 Push downward on the pry bars.
3 Remove the differential assembly.
4 Remove the special tool.





Installation
1. Install the special tools.
^ Position the Clutch Housing Gauge needle in the Differential Carrier Spreader Adapter hole.





2. CAUTION: Overspreading may damage the differential housing.

Spread the differential housing to the specification.





3. Remove the special tools.





4. NOTE: Push the differential assembly downward to fully seat the differential bearing cups in the differential housing.

Install the differential bearing cups and the differential assembly in the differential housing.
1 Position the differential bearing cups on the differential bearings.
2 Lower the differential assembly in place.





5. NOTE: Do not tighten the differential bearing cap bolts to specification at this time.

Install the differential bearing caps in their original positions.
1 Position the 2 differential bearing caps.
2 Install the 4 differential bearing cap bolts hand-tight.





6. Remove the special tools.
7. Tighten the 4 differential bearing cap bolts.
^ Tighten to 61 Nm (45 lb-ft).





8. Verify that the differential assembly rotates freely.
9. Check the ring gear backlash and remove the special tools.





10. Install the RH axle shaft.

11. NOTE: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.

NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.

NOTE: Allow the sealant to cure for one hour before filling the axle with lubricant.

Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.





12. Install the differential housing cover and the 10 differential housing cover bolts.
^ Tighten to 29 Nm (21 lb-ft).

13. Install the axle assembly.
14. If equipped, install the front axle damper-to-frame bracket.
^ Tighten to 34 Nm (25 lb-ft).

15. Fill the axle with 1.54L (3.25 pt) of lubricant.