Differential Overhaul

Fig. 1 AMC/Jeep type drive axle exploded view:

1. Remove side differential case bearings using separator and suitable puller, and place bearings with respective races.
2. Remove bolts securing ring gear, then separate ring gear from case by tapping with brass drift and hammer. Do not pry gear from case as machined surfaces will be damaged.
3. Drive out differential pinion shaft lock pin, then remove pinion shaft and thrust block.
4. Rotate side gears and remove differential pinions and thrust washers, noting installation position for assembly.
5. Remove side gears and thrust washers.
6. Inspect components as outlined and replace as needed, keeping components in order for assembly. Components that are reused should be installed in original position. Coat components with specified lubricant prior to assembly.
7. Install side gears, along with thrust washers, in respective sides of case.
8. Position thrust washers on differential pinions using grease to adhere washers.
9. Roll pinion assemblies into case, aligning pinions with shaft bores, and ensure that thrust washers are properly positioned.
10. Insert thrust block through side gear bore and align opening with differential pinion bores.
11. Align lock pin hole in pinion shaft with hole in case, insert pinion shaft and secure with new lock pin.
12. Mount ring gear on differential case with bolt holes aligned, install 2 retaining bolts in opposite holes and evenly tighten bolts to draw gear onto case. Ring gear should not be installed until side bearings have been adjusted for zero preload.
13. Install remaining ring gear bolts and torque all bolts to 105 ft. lbs. on models with 8-7/8 inch ring gear or 52 ft. lbs. on models with 7-9/16 inch ring gear.
14. Install case side bearings using suitable driver. Support case on pilot when installing second bearing to prevent damaging bearing already installed.