Differential Bearings

Differential Bearings

























Removal

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

2. Remove the 4 bolts retaining the torque arm to the rear axle housing.





3. Remove the 12 differential housing cover bolts.
- Drain the lubricant.





4. Using the Transmission Holding Fixture, mount the differential housing to a work bench.





5. NOTICE: Mark the position and location of the differential bearing caps as the arrows may not be visible. Always install the differential bearing caps in their identical locations and positions or damage to the component may occur.

Remove the 4 bolts and the 2 differential bearing caps.

6. NOTE: Use wood blocks to avoid damaging the differential housing.

Remove the differential assembly.

- Position wood blocks at the top and bottom of the differential assembly.

- Pry the differential assembly and the differential bearing shims out of the differential housing.





7. Using the 2 Jaw Puller and Step Plate, remove the differential bearing.
- Repeat for the other side.





8. Using the Drive Pinion Flange Holding Fixture, hold the pinion flange to remove and discard the pinion nut.





9. Using the 2 Jaw Puller, remove the pinion flange.





10. Use a screwdriver to force up the metal flange of the drive pinion oil seal. Install gripping pliers and strike with a hammer to remove the drive pinion oil seal.





11. Remove the drive pinion oil seal deflector, drive pinion oil seal slinger and the outer pinion bearing. Discard the outer drive pinion bearing.





12. Using the Drive Pinion Thread Protector and a soft-faced hammer, remove the differential pinion gear from the differential housing.





13. Remove and discard the drive pinion collapsible spacer.





14. Using the Bearing Puller and a suitable shop press, remove and discard the inner drive pinion bearing.





15. NOTE: Using a micrometer, measure the drive pinion bearing adjustment shim thickness. Use this measurement as a reference to compare to the shim gauge reading taken prior to installing the pinion bearing.

Remove the drive pinion bearing adjustment shim.





16. Using a brass drift and a hammer, remove any damaged differential drive pinion bearing cups from the differential housing. Tap alternately on each side of the cup to prevent it from cocking in the bore.





Installation

1. Position the Drive Pinion Bearing Cup Installer, Rear Axle Pinion Bearing Cup Installers and the inner and outer drive pinion bearing cups in their respective bores.

1. Place the Rear Axle Pinion Bearing Cup Installer on the outer drive pinion bearing cup.

2. Place the Rear Axle Pinion Bearing Cup Installer on the inner drive pinion bearing cup.

3. Install the Drive Pinion Bearing Cup Installer.





2. Tighten the Drive Pinion Bearing Cup Installer to fully seat the differential drive pinion bearing.





3. NOTE: If a feeler gauge of the specification shown can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.

Make sure the differential pinion bearing cups are correctly seated.





4. NOTICE: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly or damage to the component may occur.

NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.

Install the new drive pinion bearings, Drive Pinion Depth Gauge/Aligner, Drive Pinion Gauge Tube, Drive Pinion Depth Gauge/Aligner and Adapters as shown.









5. NOTE: This step duplicates drive pinion bearing preload.

Tighten the Adapter to the specified rotational torque.

- Tighten to 2.2 Nm (20 lb-in) rotational torque.





6. NOTE: Position the Adapter so it does not contact the housing.

NOTE: Offset the Adapter to obtain an accurate reading.

Rotate the Adapter several half turns to seat the drive pinion bearings. Position the Adapter as shown.





7. Install the Drive Pinion Gauge Tube, the 2 bearing caps and the 4 bolts.
- Tighten to 105 Nm (77 lb-ft).





8. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the drive pinion bearing adjustment shim thickness between the Adapter and the gauge tube. A slight drag indicates correct shim selection.





9. Position the drive pinion bearing adjustment shim and the inner pinion bearing on the drive pinion gear stem.





10. Using the Bearing/Oil Seal Plate and Drive Pinion Bearing Cone Installer and a suitable press, firmly seat the drive pinion bearing adjustment shim and inner pinion bearing on the drive pinion gear stem.





11. NOTE: Make sure the splines on the drive pinion gear stem are free of burrs. If burrs are evident, remove them using a fine crocus cloth.

Place a new differential drive pinion collapsible spacer on the drive pinion gear stem against the pinion stem shoulder.





12. Install the outer pinion bearing and the drive pinion oil seal slinger.





13. NOTE: If the drive pinion seal becomes misaligned during installation, remove it and install a new drive pinion seal.

NOTE: Coat the drive pinion seal lips with long-life grease.

Using the Drive Pinion Oil Seal Installer, install the new drive pinion seal.





14. Install the drive pinion gear with the differential drive pinion collapsible spacer in the differential housing.





15. Align the pinion flange to the pinion index marks.





16. Using the Drive Pinion Flange Installer, install the pinion flange.





17. NOTICE: Do not, under any circumstance, loosen the pinion nut to reduce drive pinion bearing preload. If it is necessary to reduce drive pinion bearing preload, install a new differential drive pinion collapsible spacer and pinion nut or damage to the component may occur.

NOTE: Remove the Drive Pinion Flange Holding Fixture while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench.

Use the Drive Pinion Flange Holding Fixture to hold the pinion flange while tightening the pinion nut.

- Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (lb-in) torque wrench.





18. Tighten the pinion nut to set the drive pinion bearing preload. Refer to the torque specification for drive pinion bearings in the Specifications information.





19. Using the Differential Carrier Bearing Installer, press the left and right differential bearing on the differential assembly.





20. Install the differential assembly in the following sequence.

1. Position the 2 differential bearing cups on the differential bearings.

2. Lower the differential assembly in place.

21. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.

Install a differential bearing shim of the thickness shown on the LH side of the differential case.





22. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.

Install the left bearing cap and loosely install the 2 bearing cap bolts.





23. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.

Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.





24. Install the right bearing cap and 2 bolts.

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





26. Rotate the differential case to make sure it turns freely.





27. Adjust the ring gear backlash. For additional information, refer to Ring Gear Backlash Adjustment Adjustments.

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