Standard One-Piece Differential

Fig. 5 Typical differential case bearing removal:

DISASSEMBLY

1. On models with rear axle speed sensor, remove pulse spider using suitable puller.
2. Inspect differential case side bearings and remove, as needed, using suitable puller, Fig. 5. If differential case bearings are replaced, press bearing races from side bearing caps and housing (as equipped) using suitable spacers. Take care not to distort caps and note installation position of bearing race shims, if equipped.
3. Remove and discard ring gear retaining bolts, then tap gear from case.
4. Remove differential pinion shaft as follows:
a. On all 300 series models, drive out pin securing pinion shaft, then remove shaft from case.

Fig. 6 Differential pinion shaft removal. Models w/standard differential:

b. On all models except 300 series, drive pinion shaft out of retaining ring in direction ``A'' shown in Fig. 6, then remove shaft.
5. Mount differential case in vise with one side gear opening facing up, taking care not to damage machined surfaces.

Fig. 7 Typical differential pinion removal. Models w/standard differential:

6. Insert drive flange into side gear and rotate flange to position differential pinions at openings in case, Fig. 7, then remove pinions and side gears along with shims and diaphragm springs. Keep all components in order to ensure proper assembly. Components that are reused should be installed in original position.
7. Clean components with suitable solvent, blow dry with compressed air, then coat components with axle lubricant to retard corrosion.
8. Inspect components and replace any that are damaged, distorted or excessively worn, noting the following:
a. Mate side bearings with races and check operation. Replace bearings that are damaged, scored or that fail to operate properly.
b. Inspect pinions and side gears and replace as an assembly if teeth are broken, excessively worn or deeply scored.
c. Inspect case for damaged or distorted ring gear flange, and worn side gear bores and bearing surfaces.
d. Inspect ring gear for damage, distortion, and uneven or excessive wear. Ring gear and pinion must be replaced as an assembly.

Fig. 8 Side gear thrust washer & diaphragm spring installation. Exc. limited slip differential:

1. Ensure that lock ring for pinion shaft is properly seated in groove.
2. Coat side gears with axle lubricant, then install diaphragm spring and shim on each gear with inside curved surface of spring facing gear, Fig. 8.
3. Mount side gear assemblies in case, then insert drive flanges to center gears.

Fig. 9 Spreading side gears for pinion installation:

4. Install spreader tool as shown in Fig. 9, then tighten bolt on tool until side gear can just be turned with drive flange.
5. Coat differential pinions and shaft with axle lubricant, position pinions opposite each other in mesh with side gears, then rotate drive flange to roll pinions into alignment with shaft bores in case.

Fig. 6 Differential pinion shaft removal. Models w/standard differential:

6. When pinions are properly aligned, remove spreader tool, insert tapered mandrel through pinion and case bores, from direction ``E'', Fig. 6.
7. Fit chamfered end of pinion shaft into mandrel, then press pinion shaft into position as follows:
a. If hydraulic press is used, monitor applied force carefully, and stop pressing when pressure reading increases, indicating that clip has engaged groove in shaft. Applying excessive force after clip engages groove in shaft will damage retaining clip. Do not push back on pinion shaft after engaging clip.
b. If press is not available, press shaft in by hand until 3/8 to 3/4 inch of shaft remains protruding from case.
c. Install puller 008500 or equivalent on case with forcing screw bearing on pinion shaft.
d. Tighten forcing screw with torque wrench until a reading of 16 ft.lbs. is obtained. Lubricate forcing screw prior to tightening, and ensure that force is applied to pinion shaft in an even, progressive manner.

Fig. 10 Blocking side gear for clearance check. Models w/standard differential:

8. Position washer 331441 against face of side gear and thread bolt 331431 into washer from opposite side of gear, then tighten bolt hand tight, Fig. 10.

Fig. 11 Measuring side gear clearance:

9. Mount suitable dial indicator on case with plunger bearing against face of side gear, Fig. 11, then zero indicator.
10. Tighten bolt to compress diaphragm spring, then record indicator reading.
11. Loosen bolt and rotate side gear, checking play as outlined at 3 evenly spaced positions.
12. Repeat steps 8 through 11 for remaining side gear, taking average 3 readings for each gear.
13. If average reading for each gear is not .0012 to .0040 inch, disassemble differential and replace side gear shims as needed, to obtain specified clearance. Select shims to provide clearance as close to .0012 inch as possible. After replacing shims, repeat clearance check to ensure proper adjustment.
14. Install guide pins in 2 opposite ring gear bolt holes, heat gear to 212 degrees F, then mount gear on case.
15. Apply locking compound to threads of new ring gear bolts, remove guide pins and install bolts hand tight. Do not reuse ring gear bolts. Always use new bolts of the proper grade and dimension when installing ring gear.
16. Tighten ring gear bolts evenly in crossing pattern until a torque of 72-80 ft.lbs. is obtained, then tighten each bolt an additional 50-55 degrees, maintaining crossing pattern during final tightening.
17. Press side bearings onto differential case and bearing races into bearing caps, ensuring that bearings and races remain matched.
18. Ensure that drive flange retaining rings are properly installed with both ends of ring fully seated in case groove.