Differential & Final Drive Assembly

1. Remove final drive internal gear, internal gear thrust bearing, sun gear and sun gear to differential carrier thrust bearing, see image.





2. If governor drive gear needs replacement, remove using suitable puller, see image. Install governor drive gear using a soft faced hammer until seated on carrier.

3. Check differential side gears and pinions for wear or damage, see step 1 image. If replacement is required:





a. Remove differential shaft retaining pin only in direction shown in image.

b. Pull out differential shaft and rotate pinion gears and thrust washers until they can be removed from the housing window. Slide side gears and thrust washers from housing.

c. Inspect thrust washers for scoring or other damage.

d. Reverse procedure to assemble using petroleum jelly to secure thrust washer gears. Install pinion shaft retaining pin in correct direction.

4. Inspect final drive sun gear to differential roller bearing thrust washer for wear or damage.





5. Inspect the final drive pinions for excessive wear or damage. Check pinion endplay, see image. Endplay should be .24 -.63 mm (.009-.025 inch). If necessary to replace pinion proceed as follows:

a. Remove pinion pin snap ring and pinion pins.

b. Carefully remove pinions together with thrust washers to prevent dropping needle bearings.

c. Remove both sets of needle bearings and spacer from each pinion.

d. Inspect all parts for wear or damage.

e. install a steel thrust washer on pinion pin retaining it with petroleum jelly.

f. Install 18 needle bearings on bottom of pinion pin followed by spacer and the next row of 18 needle bearings retaining all parts with petroleum jelly. Install bearings into pinion.

g. Install a steel thrust washer on other side of pinion. Install bronze thrust washers on each side of pinion on top of the steel thrust washers retaining parts with petroleum jelly.

h. Remove pinion pin from pinion and bearing assembly, then install assembly into carrier and insert pinion pin.

i. Align all pinion pin steps to the outside and install snap ring.

6. Check final drive sun gear to differential carrier thrust bearing and install with outer race against carrier.





7. Check final drive sun gear for wear or damage and install step side facing up, see image.





8. Check final drive internal gear and bushing for damage or wear. Check sun gear to internal gear thrust bearing and install it with cupped race side on final drive internal gear retaining it with petroleum jelly, see image. Install internal gear on final drive carrier.

9. Check differential to case selective thrust washer and install on differential carrier retaining with petroleum jelly.





10. Check differential to case roller bearing and install onto differential carrier with the inner race against the selective thrust washer, see image. Retain with petroleum jelly.





11. Install differential carrier assembly into case, see image.

12. Install final drive internal gear spacer with the cupped side against the internal gear. The parking pawl opening in the spacer must be aligned with the parking pawl opening in the case.

13. Install the 2.36 mm (.092 inch) thick case snap ring with the gap facing away from parking pawl opening.

14. Check the final drive to case endplay as described in "Disassembly."