Differential Bearings
Differential Bearings
Removal
1. Remove the axle assembly.
2. Drain the front axle assembly.
1 Remove the 10 differential housing cover bolts.
2 Remove the differential cover.
3. Install the special tools on the differential housing.
4. Install the special tool fixture on the adapters and mount the assembly to bench.
5. Remove the 2 differential bearing caps.
1 Remove the 4 differential bearing cap bolts.
2 Remove and identify the 2 differential bearing caps.
6. Install the special tools.
7. CAUTION: Overspreading can damage the differential housing.
Spread the differential housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the differential carrier spreader screw.
3 Remove the dial indicator.
8. CAUTION: Use wood blocks to avoid damaging the differential housing.
Remove the differential assembly from the housing.
1 Position the wood blocks.
2 Push downward on the pry bars.
3 Remove the differential assembly.
4 Remove the special tool.
9. Remove and discard the 10 differential ring gear bolts and the differential ring gear.
^ Use a drift punch to separate the differential ring gear from the differential case.
10. Assemble the special tools.
11. Position the special tool on the differential bearing.
12. Using the special tool, remove the RH and LH differential bearings.
13. Using the special tool to hold the pinion flange, remove and discard the pinion nut and washer.
14. Using the special tool, remove the pinion flange.
15. Using a soft-face hammer, remove the pinion from the differential housing.
1 Hold the pinion inside the differential housing.
2 Use a soft-face hammer to remove the pinion from the outer pinion bearing.
16. Using gripping pliers and a hammer, remove the drive pinion oil seal.
17. Remove the front axle drive pinion shaft oil slinger and the outer pinion bearing.
18. Remove the inner pinion bearing.
1 Position the special tool under the bearing.
2 Using a shop press, remove the inner pinion bearing.
19. Remove the drive pinion position shim.
^ Measure and record the thickness of the pinion position shim for reference during installation.
20. NOTE: To prevent it from becoming misaligned in the bore, remove the outer pinion bearing cup by tapping alternately on each side of the outer pinion bearing cup with a brass drift.
Remove the outer pinion bearing cup.
21. NOTE: To prevent it from becoming misaligned in the bore, remove the inner pinion bearing cup by tapping alternately on each side of the inner pinion bearing cup with a brass drift.
Remove the inner pinion bearing cup.
Installation
1. NOTE: Lubricate the new differential drive pinion bearing cups with rear axle lubricant.
Install the new inner and outer drive pinion bearing cups.
^ Using the special tools, install the new drive pinion bearing cups.
2. Assemble and position the following in the differential housing.
1 Position the screw.
2 Position the aligning adapter.
3 Position the inner pinion bearing.
4 Position the gauge disc.
5 Position the gauge block.
6 Position the outer pinion bearing.
7 Thread on the handle.
3. Using a Nm torque wrench, tighten the handle.
^ Tighten to 2.5 Nm (22 lb-inch).
4. NOTE: Offset the Gauge Block to obtain an accurate reading.
Rotate the Gauge Block several half turns to make sure the pinion bearings seat correctly. Position the special tool as shown.
5. Install the special tool.
1 Position the special tool.
2 Install the 2 differential bearing caps.
3 Install the 4 differential bearing cap bolts.
^ Tighten to 61 Nm (45 lb-ft).
6. NOTE: Selection of a drive pinion position shim that is too thick results in deep tooth contact at final assembly. Do not attempt to force the feeler gauge or drive pinion position shim between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.
Using a feeler gauge or a flat, clean drive pinion position shim, measure between the Gauge Block and the Gauge Tube. Record the measurement.
^ Remove the special tools after determining the correct drive pinion position shim thickness.
7. Select the correct thickness drive pinion position shim.
^ New drive pinion position shims are available in the following sizes:
^ Notice the plus (+), minus (-) or zero (0) etching on the drive pinion, and adjust the thickness of the new shim. If the etching is positive, subtract the number from the selected position shim. If the etching is negative, subtract the number from the selected position shim.
^ The selected shim thickness should be very close to the recorded thickness of the original position shim.
8. Install the new selected drive pinion position shim and the new inner pinion bearing on the drive pinion.
^ Using the special tool and a suitable press, seat the inner pinion bearing firmly against the drive pinion position shim.
9. Install a new collapsible spacer.
10. Install the new outer drive pinion bearing and the drive pinion oil slinger
11. CAUTION: The drive pinion oil seal must be fully seated all the way around or drive pinion oil seal damage will occur.
NOTE: Lubricate the drive pinion oil seal lips with rear axle lubricant.
Using the special tool, install the drive pinion oil seal.
12. Lubricate the drive pinion gear splines with rear axle lubricant.
13. Install the drive pinion gear into the axle housing.
14. CAUTION: Never use a metal hammer on the pinion flange or install the flange with power tools or damage to the component may occur.
Align the pinion flange.
15. Using the special tool, install the pinion flange.
16. CAUTION: Do not loosen the pinion nut to reduce pinion bearing preload or damage to the component may occur. Install a new collapsible spacer and pinion nut if pinion bearing preload reduction is necessary.
Using the special tool to hold the pinion flange, tighten the pinion nut to set the pinion bearing preload.
^ Tighten the pinion nut, rotating the pinion occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing preload readings by rotating the pinion with a Nm torque wrench. The final reading must be 1.7-3.4 Nm (15-30 lb-inch).
17. Install the special tools.
18. Position the differential assembly in the differential housing.
19. NOTE: Repeat this step until obtaining a consistent reading.
Measure the total end play.
1 Install the special tool.
2 Force the differential assembly as far as possible away from the indicator. Position the indicator tip on the machined surface and adjust it to measure full travel. With force still applied, set the indicator to zero.
3 Force the differential assembly as far as possible in the opposite direction.
4 Record the total end play reading on the Differential Bearing Shim Selection Procedure Worksheet, Line A in this procedure.
20. Remove the special tool, then remove the differential assembly.
1 Remove the special tool.
2 Remove the differential assembly.
21. CAUTION: Do not reuse the original differential ring gear bolts.
Using a suitable press, install the differential ring gear.
1 Position the differential ring gear and the differential assembly. Start 3 new differential ring gear bolts to align the holes in the differential ring gear and the differential assembly.
2 Using a suitable press, install the differential ring gear.
22. Install the 7 remaining new differential ring gear bolts.
^ Tighten to 122 Nm (90 lb-ft).
23. Install the special tools and position the differential assembly in the differential housing.
1 Install the special tool.
2 Position the differential assembly in the differential housing.
24. Position the special tool.
25. Force the differential ring gear into mesh with the pinion gear (zero backlash). With force still applied, set the special tool to zero.
26. Force the differential ring gear away from the pinion gear as far as possible. Record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line D in this procedure.
27. Remove the special tool.
28. Remove the differential assembly from the differential housing. Remove the special tools from the differential assembly hubs.
29. Complete the worksheet and select the appropriate thickness differential bearing shims. New differential bearing shims are available in 0.0762 mm (0.003 inch), 0.127 mm (0.005 inch), 0.254 mm (0.010 inch) and 0.762 mm (0.030 inch) thickness.
Differential Bearing Shim Selection Procedure Worksheet
Differential Bearing Shim Selection Procedure Worksheet:
30. Install the selected differential bearing shims and the new LH and RH differential bearings.
1 Position the differential bearing shims and the differential bearing.
2 Using a suitable press, install the differential bearing.
^ Repeat this step for opposite side of the differential assembly.
^ Most axles will have the larger amount of shims on the differential ring gear side and the smaller amount on the case side.
31. Install the special tools.
^ Position the clutch housing gauge needle in the differential carrier spreader adapter hole.
32. CAUTION: Overspreading can damage the differential housing.
Spread the differential housing to the specification.
33. Remove the dial indicator.
34. NOTE: Push the differential assembly downward to fully seat the differential bearing cups in the differential housing.
Install the 2 differential bearing cups and the differential assembly in the differential housing.
1 Position the 2 differential bearing cups on the 2 differential bearings.
2 Lower the differential assembly in place.
35. NOTE: Do not tighten the differential bearing cap bolts to specification at this time.
Install the 2 differential bearing caps in their original positions.
1 Position the 2 differential bearing caps.
2 Install the 4 differential bearing cap bolts hand-tight.
36. Remove the special tools.
37. Tighten the 4 differential bearing cap bolts.
^ Tighten to 61 Nm (45 lb-ft).
38. Verify that the differential assembly rotates freely.
39. Using the special tools, measure the backlash at 3 equally spaced points on the differential ring gear.
1 Mount the special tools.
2 Position the special tools.
3 Zero the indicator.
4 Turn the differential ring gear without turning the pinion gear. Record the measurement.
^ The backlash tolerance is 0.13 mm (0.005 inch) to 0.20 mm (0.008 inch) and cannot vary more than 0.05 mm (0.002 inch) between points checked.
^ If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount.
40. Remove the special tools.
41. Apply marking compound and rotate the differential assembly 5 complete revolutions.
42. Verify an acceptable pattern check.
43. Install the RH axle shaft.
44. NOTE: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.
NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.
NOTE: Allow the sealant to cure for 1 hour before filling the axle with lubricant.
Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.
45. Install the differential housing cover and the 10 differential housing cover bolts.
^ Tighten to 29 Nm (21 lb-ft).
46. Install the axle assembly.
47. Remove the fill plug and fill the axle with rear axle lubricant to 9.56 mm (0.38 inch) below the bottom of the filler hole.
48. Install the fill plug.
^ Tighten to 27 Nm (20 lb-ft).