Clutch & Differential Housing

1992

Disassemble
Remove bearings and bushings only if there is evidence of damage or a mating component is being replaced.

1. Remove bolts (179) and retainer (178).

2. Remove output shaft race (56) using output shaft bearing cup removal tool No. J-36038 and slide hammer tool No. J-23907, or equivalents.

3. Remove bolts (159), washers (160), spacer (161) and plate (162).

4. Remove bolt (18) and reverse rail guide (19).

5. Remove axle shaft seal (23).

6. Remove differential race (76) and selective shim (73) using bearing removal tool No. J-26941 and slide hammer tool No. J-23907, or equivalents.

7. Remove seal (164).

8. On models with external clutch release, remove bushing (163) using clutch shaft upper bushing removal tool No. J-36037, or equivalent (view B).

9. On models with internal clutch release, remove bolt (214), then tap on clutch fork finger lightly to drive out upper bearing (217).

10. Remove clutch shaft (165) or (216).

11. On models with external clutch release, remove bushing (177) using reverse shift rail bushing removal tool No. J-36032 and slide hammer tool No. J-23907, or equivalents (view C).

12. On models with internal clutch release, install clutch shaft inner bearing guide tool No. J-37107-2, or equivalent, into bearing. Drive clutch shaft inner bearing removal tool No. J-37107-1, or equivalent, through the guide tool and bearing case. Screw tool No. J-37107-1, or equivalent, into bearing case and slide hammer out. Remove bearing (217) (view C).

13. On all models, remove bearing sleeve assembly (21) using input bearing assembly removal tool No. J-35824, or equivalent, and hydraulic press. Refer to view B.

14. Remove bushing (176) using shaft rail bushing removal tool No. J-36029, or equivalent, with small end of second adapter into bushing.

15. Remove drain plug (79) and washer (80).

16. Remove breather assembly (166).


Inspection
Inspect all components for excessive wear and/or damage. Replace worn and/or damaged components as required.


Assemble
Attaching bolts (159) and (179), require a small amount of thread sealant part No. 12345382, or equivalent. Torque attaching bolts to 16 ft. lbs.

Do not install differential bearing race (76) and axle seal (23) or shim (73). Installation of these components will take place after the differential bearing selective shim procedure has been completed.

1. Install drain plug (79) and new washer (80). Tighten to specifications.

2. Install bushings (176) using shaft rail bushing installation tool No. J-36029, or equivalent, as follows:

a. Place new bushing on second adapter and retain between first and second tool parts and tool No. J-36190, or equivalent (view A).

b. Bushing (176) must not protrude into case side of clutch housing.

3. Install bearing sleeve assembly (21), pressing down on installation tool No. J-25824, or equivalent (view B). Ensure oil seepage hole is installed downward in clutch housing.

4. On models with internal clutch release, proceed as follows:

a. Install bushing (177) using installation tool No. J-36033 and driver handle tool No. J-361 90, or equivalents (view C).

b. Install clutch shaft (165) or (216).

5. On models with external clutch release, install bushing (163) using tool No. J-36037, or equivalent, with outer end of bushing flush with bottom of seal bore.

6. On models with internal clutch re lease, install bearing (217) using clutch shaft outer bearing installation tool No. J-36720-1, or equivalent.

7. On all models, install seal (164).


8. Install reverse rail guide (19). Ensure guide short end is in bore. Tighten guide bolt to specifications.

9. Install bearing race (56) as follows:

a. Align race cutouts with slots in case.

b. Using differential and output shaft bearing cup installation tool No. J-23423-A and driver handle tool No. J-8092, or equivalents, install race (56) with recessed side facing upward to clear ring gear.

10. Install output bearing race retainer (178) and bolts (179). Tighten bolts to specifications.

1. Install shift interlock plate (162), spacers (161), washers (160) and bolts (159). Tighten bolts to specifications.

12. Install breather assembly (166).

13. On models equipped with internal clutch release, install studs (218). Tighten studs to specifications.
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1993-94

Disassemble
1. Remove bolts (179) and retainer (178).

2. Remove output shaft race (56) using race remover tool No. J-36038 and slide hammer and adapter set tool No. J-23907, or equivalents (view A).

3. Remove bolts (159) and interlock plate (162), then the axle shaft seal (23).

4. Remove input shaft bearing and seal assembly (21) using input bearing assembly remover/installer or equivalent, and hydraulic press (view B).

5. Remove drain plug (79) and washer (80), then the breather assembly. Do not remove metal tube from case.

6. Remove differential carrier support race (76) using race remover tool No. J-26941 and slide hammer and adapter set tool No. J-23907, or equivalents (view B), Fig. 20. If race (76) is removed, preload differential bearing before assembly.

7. Remove selective shim (73).


Inspection
Inspect all components for excessive wear and/or damage. Replace worn and/or damaged components as required.


Assemble
Do not install differential carrier support bearing race (76) and axle shaft seal (23) or selective shim (73). Installation will be after differential bearing selective shimming.

1. Install selective shim (73) and differential carrier support bearing race (76) using race installer tool No. J-26938 and universal driver handle tool No. J-8092, or equivalents (view B).

2. Install drain plug (79) and new washer (80). Tighten plug to specifications.

3. Install shift rail bushings (176) using shift rail bushing installer/remover tool No. J-36029 and universal driver handle tool No. J-36190, or equivalents (view A). Shift rail bushing (176) must not protrude into case side of clutch housing.

4. Apply thread locking compound part No. 1234382, or equivalent, to input shaft bearing and sleeve assembly case bore, then install bearing and seal assembly (21) using input bearing assembly remover/installer tool No. J-35824, or equivalent (view B).

5. Align output shaft race cutouts with alignment tangs of race retainer (178), then install output shaft race (56) using differential/output shaft bearing cap installer tool No. J-23423-A and universal driver handle tool No. J-8092, or equivalents (view A).

6. Apply thread locking compound part No. 12345382, or equivalent, to output bearing race retainer bolt threads, then install race retainer (178), recessed side up, and bolts (179). Tighten bolts (179) to specifications.

7. Apply thread locking compound part No. 12345382, or equivalent, to shift interlock plate bolt threads, then install interlock plate (162) and bolts (159). Tighten bolts (159) to specifications.

8. Install breather assembly, then apply sealant part No. 1052942, or equivalent, to axle shaft seal case bore.

9. Install axle seal (23) using race installer tool No. J-26938 and universal driver handle tool No. J-8092, or equivalents (view 0). Apply chassis grease between seal lips.