Differential Case and Ring Gear Traction-LOK(R)
Differential Case and Ring Gear Traction-Lok(R)Special Tool(s):
Material:
Disassembly
1. Remove the differential carrier.
2. Remove the 10 ring gear bolts.
3. CAUTION: Care should be taken not to damage the bolt hole threads.
Insert a punch in the bolt holes and drive the ring gear off.
4. NOTE: The anti-lock speed sensor ring cannot be reused once removed.
Remove the speed sensor ring, if required.
5. Using the special tools, remove the differential bearing.
^ Repeat for the other side.
6. Remove and discard the differential pinion shaft lock bolt and remove the differential pinion shaft.
7. WARNING: Due to the spring tension, care must be used when removing the differential clutch spring.
Remove the differential clutch spring.
8. Remove the differential gears.
1 Remove the 2 differential pinion gears.
2 Remove the 2 differential side gears.
3 Remove the 2 differential pinion thrust washers.
9. CAUTION: Keep the differential clutch packs in order. Do not mix them. They must be reassembled in the same sequence.
Remove the differential clutch packs and differential side gears and tag them right and left with the shim.
^ Clean and inspect the remaining parts of the differential case for wear or damage and install new parts as necessary.
10. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only.
Clean and inspect the differential clutch packs for wear and install new parts as necessary.
Assembly
1. CAUTION: 118 ml (4 oz) of the specified friction modifier must be used in the axle.
Prelubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.
2. CAUTION: Do not mix the differential clutch packs or shims from one side with the other.
Assemble the differential clutch packs (without the shims) on the respective differential side gears.
3. CAUTION: Select the correct mandrel to use with the Traction-Lok(R) Differential Gauge.
Place the base portion of the special tool in a vise. Install the differential clutch pack and differential side gear (without the shim) on the gauge.
4. Position the special tool hand-tight on top of the differential clutch pack.
5. Install the special tool over the disc and differential clutch pack.
6. Install the nut of the gauge over the top and base stud.
^ Tighten to 6.7 Nm (60 inch lbs.).
7. Select the thickest blade of a suitable feeler gauge that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim.
8. Remove the special tool from the clutch pack and side gear assembly.
9. Install the selected shims on the clutch pack and side gear assembly.
10. Install the differential side gear in the differential case.
11. Install the differential pinion gears with differential pinion thrust washers in the differential case.
12. Install the differential clutch spring, using a soft-faced hammer.
13. Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight.
14. Using the special tool, install the differential bearing on the differential case. Repeat for the other side.
15. Install the anti-lock speed sensor.
^ Start 2 of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes correctly.
16. Press the new anti-lock speed sensor ring and the ring gear on the differential case.
17. Install the ring gear bolts.
^ Apply sealer to the ring gear bolts.
^ Tighten to 105 Nm (77 ft. lbs.).
18. Check the torque required to rotate one differential side gear.
^ Mount the differential case and special tool in a vise.
^ The initial minimum break-away torque, if original clutch plates are used, must be within specification. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary.
19. Install the differential carrier.