Differential Case

Differential Case













Disassembly

NOTE: The Torsen(R) differential should be replaced as a unit only. Do not attempt to rebuild.

1. Remove the differential carrier. For additional information, refer to Differential Carrier .

2. NOTE: Use a drift punch to separate the ring gear from the differential case.
Remove and discard the 10 bolts. Remove the differential ring gear.






3. Remove the differential pinion shaft bolt.





4. Remove the differential pinion shaft.





5. Remove the differential pinion thrust washers and the differential pinion gears.
1. Rotate the differential pinion gears to the differential case window, and remove them.

2. Separate the thrust washers from the gears.






6. Remove the differential side gears and the differential side gear thrust washers.





Assembly

1. Lubricate the differential side gear thrust washers and the differential side gear journals with axle lubricant.

2. Position the differential side gear thrust washers on the differential side gears.





3. Position the differential side gears.





4. Lubricate the differential pinion thrust washers and the differential pinion gears with axle lubricant and assemble them.





5. Engage the differential pinion gears opposite the differential side gears.





6. Rotate the differential pinion gears to align with the differential pinion shaft bore.





7. Insert the differential pinion shaft.





8. NOTE: If a new pinion shaft bolt is unavailable, coat the threads with sealer.
Install a new differential pinion shaft bolt.

- Tighten to 30 Nm (22 lb-ft).






9. Install the differential ring gear.
1. Place the differential ring gear on the differential assembly.

2. Hand-start 3 ring gear bolts to align the holes in the differential ring gear and the differential assembly.

3. Place the differential carrier and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.

4. Press the differential ring gear into place.






10. Install the 7 remaining new bolts.
- Tighten all 10 bolts to 128 Nm (95 lb-ft).






11. Install the differential carrier. For additional information, refer to Differential Carrier .