Removal and Installation

REMOVAL
1. Raise and support vehicle.
2. Remove the lubricant fill hole plug from the differential housing cover.
3. Remove the differential housing cover and allow fluid to drain.
4. Remove axle shafts.

Fig. 23:

5. Note the installation reference letters stamped on the bearing caps and housing machined sealing surface (Fig. 23).
6. Loosen the differential bearing cap bolts.

Fig. 24:

7. Position Spreader W-129-B, utilizing some items from Adapter set 6987, with the tool dowel pins seated in the locating holes (Fig. 24). Install the hold-down clamps and tighten the tool turnbuckle finger tight.

Fig. 25:

8. Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the indicator plunger against the opposite side of the housing (Fig. 25) and zero the indicator.

CAUTION: Do not spread over 0.38 mm (0.015 inch). If the housing is over-spread, it could be distorted or damaged.

Fig. 26:

9. Spread the housing enough to remove the differential case from the housing. Measure the distance with the dial indicator (Fig. 26).
10. Remove the dial indicator.
11. While holding the differential case in position, remove the differential bearing cap bolts and caps.

Fig. 27:

12. Remove the differential from the housing. Ensure that the differential bearing cups remain in position on the differential bearings (Fig. 27).
13. Mark or tag the differential bearing cups to indicate which side of the differential they were removed from.
14. Retrieve differential case preload shims from axle housing. Mark or tag the differential case preload shims to indicate which side of the differential they were removed from.
15. Remove spreader from housing.

INSTALLATION
If replacement differential bearings or differential case are being installed, differential side bearing shim requirements may change. Refer to the Differential Bearing Preload and Gear Backlash procedures to determine the proper shim selection.

Fig. 28:

1. Position Spreader W-129-B, utilizing some items from Adapter set 6987, with the tool dowel pins seated in the locating holes (Fig. 28). Install the hold-down clamps and tighten the tool turnbuckle finger-tight.
2. Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the indicator plunger against the opposite side of the housing (Fig. 25) and zero the indicator.

CAUTION: Do not spread over 0.38 mm (0.015 inch). If the housing is over-spread, it could be distorted or damaged.

3. Spread the housing enough to install the case in the housing. Measure the distance with the dial indicator (Fig. 26).
4. Remove the dial indicator.
5. Install differential case in the housing. Ensure that the differential bearing cups remain in position on the differential bearings and that the preload shims remain between the face of the bearing cup and the housing. Tap the differential case to ensure the bearings cups and shims are fully seated in the housing.

Fig. 29:

6. Install the bearing caps at their original locations (Fig. 29).
7. Loosely install differential bearing cap bolts.
8. Remove axle housing spreader.
9. Tighten the bearing cap bolts to 77 Nm (57 ft. lbs.) torque.
10. Install the axle shafts.