Differential
DISASSEMBLY1. Remove differential side bearings:
a. Install button 8491-1 to differential case (Fig. 65).
b. Set up Tool 5048 (5048-1, -4, -6) as shown in (Fig. 66).
c. Remove differential side bearing (Fig. 67). Same procedure/tools work for both sides.
2. Remove ring gear-to-case bolts (Fig. 68) and remove ring gear.
3. Using three ring gear bolts as forcing screws (Fig. 69), separate differential support from case (Fig. 70).
4. Remove side gear thrust washer (Fig. 71).
5. Remove side gear (Fig. 72).
6. Remove long pinion shaft (Fig. 73).
7. Remove both short pinion shafts (Fig. 74).
8. Remove pinion shaft retainer (Fig. 75).
9. Remove four pinion gears and thrust washers (Fig. 76).
10. Remove side gear (Fig. 77).
11. Remove side gear thrust washer (Fig. 78).
ASSEMBLY
1. Install side gear thrust washer (Fig. 79).
2. Install differential side gear (Fig. 80).
3. Install four (4) pinion gears and thrust washers (Fig. 81).
4. Install pinion shaft retaining ring (Fig. 82).
5. Install two (2) short pinion shafts (Fig. 83).
6. Install one (1) long pinion shaft (Fig. 84).
7. Install differential side gear.
8. Install side gear thrust washer (Fig. 85).
9. Install differential support plate. Align support plate to differential case with alignment pins 8470 (Fig. 86).
10. Install thrust buttons 8491 to both bearing journals and press halves together using an arbor press (Fig. 87).
11. Install ring gear into position, start three ring gear-to-differential case bolts by hand (120° apart), and install alignment pins 8470 (Fig. 88).
12. Torque three ring gear bolts to draw ring gear into position. Remove alignment pins, install remaining ring gear-to-differential case bolts and torque to 95 Nm (70 ft. lbs.) (Fig. 89).
13. Install tapered roller bearings using installer 8473 and an arbor press (Fig. 90). Insert button 8491 on opposite journal to protect journal and/or bearing during press operation. Repeat the same operation on opposite side.
14. Measure and verify differential side gear end play.