Two Piece Differential

Disassembly

Keep all components in order during disassembly.
1. Remove bolts securing differential case cover, then the cover and side gear assembly.
2. Remove differential pinion and pinion shaft assemblies, noting position for installation.
3. Remove side gears, along with shim and diaphragm spring from each case half, keeping components in order for assembly.
4. Remove ring gear and side bearings as outlined for ``Standard One-Piece Differentials.''
5. Clean components with suitable solvent, dry with compressed air and coat components with axle lubricant to prevent corrosion.
6. Inspect components and replace any that are damaged, distorted or excessively worn.

Assembly & Adjustment

Components that are to be reused should be installed in original position to ensure proper operation.
1. Install ring gear side gear and one pinion shaft/pinion gear assembly, then the case cover, and torque cover bolts to 16 ft.lbs.
2. Mount suitable dial indicator on case with plunger inserted through drive flange opening and bearing against face of side gear.
3. Press side gear into contact with pinions using screwdriver, then zero dial indicator.
4. Pull side gear back against case and record dial indicator reading.
5. Subtract .002 inch from measurement obtained in step 3, then select side gear shim and spring as close as possible to remainder to obtain .002-.004 inch side gear clearance.
6. Repeat steps 1 through 5 with case cover side gear.

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

7. Disassemble unit, install selected shims and springs on respective side gears with concave side of spring facing gear, Fig. 8.
8. Coat all components with axle lubricant, reverse disassembly procedure to complete assembly, then evenly torque case cover bolts to 16 ft.lbs. in crossing pattern.