Differential Assembly
Disassembly
1. Using holding fixture J-42832 and holding fixture base J-3289-20, fix the differential assembly to the bench.
2. Apply a setting mark to the side bearing cap and the differential carrier then remove bearing cap.
3. Remove differential cage assembly.
4. Remove side bearing outer race. After removal, keep the right and left hand side bearing assemblies separate to maintain inner and outer race combinations.
5. Remove side bearing by using remover J-42379 and adapter J-8107-3. Select collet halves 44803 in remover kit J-42379 for side bearing removal and insert is not required for this operation.
6. Note the thickness and position of the shims then remove adjust shim.
7. Remove the flange nut and washer by using pinion flange holder J-8614-01 after raising up its staked parts completely.
8. Removed flange assembly.
9. Remove the drive pinion assembly using a soft metal rod and a hammer.
10. Remove collapsible spacer.
11. Remove the inner bearing by using remover J-42379. Select insert 303174 and collet halves 44803 in remover kit J-42379 for inner bearing removal.
12. Remove adjust shim.
13. Remove oil seal.
14. Remove outer bearing.
15. Remove the inner bearing outer race (1) and the outer bearing outer race (2) by using a brass bar and a hammer.
Reassembly
1. Install outer bearing outer race by using installer J-44461 and grip J-8092.
2. Install inner bearing outer race by using installer J-44462 and grip J-8092.
3. Adjust the drive pinion mounting distance as follows:
1. Apply gear oil to the inner and outer drive pinion bearing. Clean the pinion setting gauge set. Then install the gauge set together with the inner and outer bearings.
Install gauge plate J-42826 (3), inner pilot J-42827 (2), stud and nut J-21777-43 (4) and outer pilot J-42824 (1) through inner and outer bearings.
2. Tighten the nut to the specified torque.
Torque: 2.3 Nm (20 inch lbs.)
3. Clean the side bearing bores. Place discs and dial indicator on to arbor, and place tool into position in side bearing bores. Install and tighten the bearing caps to the specified torque.
4. Set the dial indicator J-8001 to "0". Place it on the mounting post of the gauging arbor with the contact button touching the indicator pad. Force the dial indicator downward until the needle has made a half turn clockwise.
Tighten down the dial indicator in this position.
5. Position the plunger on the gauge plate. Move the gauging arbor slowly back and forth and locate the position at which the dial indicator shows the greatest defection. At this point, once again set the dial indicator to "0". Repeat the procedure to verify the "0" setting.
6. After the ZERO setting is obtained, rotate the gauging arbor until the dial indicator rod does not touch the gauging plate. Record the number the dial indicator needle points to.
7. Record the pinion depth code on the head of the drive pinion. The number indicates a necessary change in the pinion mounting distance. A plus number indicates the need for a greater mounting distance (which can be achieved by decreasing the shim thickness). A minus number indicates the need for a smaller mounting distance (which can be achieved by increasing the shim thickness). If examination reveals pinion depth code "0", the pinion is "nominal".
8. Select the shim thickness using the chart;
Shim Thickness Chart
1. Place the shim (1) on the drive pinion, then install the inner bearing (2) onto the pinion by using installer J-42828 and a press.
Note: Do not apply pressure to the roller cage. Apply pressure only to the inner race.
5. Install collapsible spacer. Discard the used collapsible spacer and install a new one.
6. Install drive pinion shaft assembly.
7. Install outer bearing.
8. Use oil seal installer J-37263 to install a new oil seal that has grease on seal lip.
9. Install flange assembly.
10. Install flange nut and washer.
1. Apply lubricant to the pinion threads.
2. Using the pinion flange holder J-8614-01, tighten the nut only enough to remove the shaft end play.
Note: Discard used flange nut and install new one.
3. Adjust pinion bearing preload.
a. Measure the bearing preload by using a torque meter and note the scale reading required to rotate the flange.
b. Continue tightening flange nut until the specified starting torque is obtained.
Starting torque: 1.1 - 1.6 Nm (10 - 14 inch lbs.)
Note:
a. Do not overtighten or loosen and then retighten the nut.
b. Pinion nut torque should be in the range of 298 - 380 Nm (220 - 281 ft. lbs.).
4. Using punch J-39209, stake the flange nut at two points.
Note: When staking, be sure to turn the nut to ensure that there is no change in bearing preload. Make sure of preload again as instructed in 3.
11. Adjust ring gear backlash.
1. Attach the side bearing to the differential assembly without shims by using installer J-42829 and grip J-8092.
2. Insert the differential cage assembly with bearing outer races into the side bearing bores of the carrier.
3. Using two sets of feeler gauges, insert a feeler stock of sufficient thickness between each bearing outer race and the carrier to remove all end play. Make certain the feeler stock is pushed to the bottom of the bearing bores.
Mount the dial indicator J-8001 on the carrier so that the indicator stem is at right angles to a tooth on the ring gear.
4. Adjust feeler gauge thickness from side to side until ring gear backlash is in the specified range.
Backlash: 0.13 - 0.2 mm (0.005 - 0.008 inch)
With zero end play and correct backlash established, remove the feeler gauge packs, determine the thickness of the shims required and add 0.05 mm (0.002 inch) to each shim pack to provide side bearing preload. Always use new shims.
5. Remove side bearing by using remover J-42379 and adapter J-8107-3.
12. Install the side bearings together with the selected shims by using installer J-42829 (2) and grip J-8092 (1).
13. Install side bearing outer race.
14. Install differential cage assembly.
15. Align the setting marks (1) applied at disassembly then install the bearing cap.
16. Tighten the bolt to the specified torque.
Torque: 108 Nm (80 ft. lbs.)
Gear Tooth Contact Pattern Check and Adjustment
1. Apply a thin coat of Prussian blue or equivalent to the faces of the 7 - 8 teeth of the ring gear. Check the impression of contact on the ring gear teeth and make necessary adjustment as described in illustration if the contact is abnormal.