Differential Carrier

Differential Carrier





















Removal

1. Remove the axle assembly. For additional information, refer to Axle Assembly Axle Assembly.

2. Remove the 10 bolts and the differential housing cover.
- Drain the fluid.





3. Using the Transmission Fluid Pump Remover and Slide Hammer, remove the intermediate shaft.





4. Remove the 4 bolts and the axle housing tube.





5. NOTICE: The fixture mounting bolts must have the minimum specified thread engagement in the carrier or damage to the component may occur.

Install the Transmission Holding Fixture.





6. NOTICE: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier or damage to the component may occur.

Install the Differential Housing Spreader Plate and Adapter for Differential Housing Spreader.





7. Position the Differential Carrier Spreader on the spreader adapters.





8. Install the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.
- Position the adapter tip in the spreader adapter hole.





9. NOTICE: Overspreading may damage the component.

Spread the axle housing to the specification.

1. Adjust the Dial Indicator Gauge to zero.

2. Tighten the housing spreader screw to spread the axle housing to the specification.

3. Remove the Dial Indicator Gauge with Holding Fixture.





10. NOTICE: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the differential bearing caps in their original positions or damage to the component may occur.

Mark and remove the 2 differential bearing caps.

1. Remove the 4 differential bearing cap bolts.

2. Remove the 2 differential bearing caps.





11. NOTE: Use wood blocks to avoid axle housing damage.

NOTE: Index-mark the position of the differential bearing shims. The differential bearing shims must be installed in their original locations and positions.

Remove the differential carrier from the axle housing.

1. Position the wood blocks.

2. Position and push down on the 2 pry bars.

3. Remove the differential carrier.

4. Remove the Differential Carrier Spreader.





Installation

1. NOTE: Make sure the Dial Indicator needle is in the spreader adapter hole.

Install the Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier Spreader.





2. NOTICE: Overspreading may damage the component.

Spread the axle housing to the specification.

- Remove the Dial Indicator.





3. NOTICE: Never attempt to drive the differential bearing shim in place. Permanent damage to the machined axle housing surfaces may occur.

Position the differential bearing shims.

1. Apply a light coating of grease to one side of the differential bearing shims to help hold them in place.

2. Position the differential bearing shims.





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

Position the differential carrier.

1. Position the differential bearing cups on the differential bearings.

2. Lower the differential assembly in place between the differential bearing shims.





5. Install the differential bearing caps in their original positions and tighten with the housing still spread.

1. Position the 2 differential bearing caps.

2. Install the 4 differential bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).

3. Remove the Differential Carrier Spreader.





6. Install the Dial Indicator Gauge with Holding Fixture.





7. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the differential ring gear backlash at 4 equally spaced points.

1. Attach the Dial Indicator Gauge with Holding Fixture.

2. Position the Clutch Housing Gauge tip centrally on a drive tooth.

3. Zero the Dial Indicator.

4. Turn the differential ring gear without turning the drive pinion gear.





8. Install a new O-ring and new circlips on the intermediate shaft ends.





9. Install the axle housing tube and the 4 bolts.
- Tighten to 73 Nm (54 lb-ft).





10. Install a new stub shaft seal. For additional information, refer to Stub Shaft Pilot Bearing and Seal Stub Shaft Pilot Bearing and Seal.

11. Insert the intermediate shaft and engage the circlip with the differential side gear.

12. Remove the axle assembly from the Transmission Holding Fixture and place it on the bench.

13. NOTE: Remove all of the silicone gasket and make sure the machined surfaces are free of oil before applying the new silicone gasket.

NOTE: Install the differential housing cover within 15 minutes of applying the silicone gasket, or it will be necessary to remove and reapply silicone gasket. If possible, allow one hour before filling with lubricant to make sure the silicone gasket has cured.

Fill the sealing groove on the differential housing cover with silicone gasket.





14. Install the differential housing cover and the 10 differential housing cover bolts.
- Tighten to 32 Nm (24 lb-ft).





15. Fill the axle housing with axle lubricant and install the fill plug.
- Tighten to 25 Nm (18 lb-ft).





16. Install the axle assembly. For additional information, refer to Axle Assembly Axle Assembly.