Differential Case

Differential Case





Special Tool(s)

Removal
1. Remove the axle shafts.






2. CAUTION: Index mark the position of the differential bearing caps, as arrows may not be visible. The differential bearing caps must be installed in their identical locations and positions.

Remove the differential bearing cap bolts and the differential bearing caps.






3. WARNING: Be careful not to allow the differential assembly to fall.

CAUTION: Place a wood block between the pry bar and the axle housing to protect the machined surface from damage.

Using a pry bar and wood block, remove the differential assembly from the axle housing.

Installation





1. Install the differential assembly in the axle housing.





2. Install a differential bearing shim on the LH side.






3. CAUTION: Mark the position of the differential bearing caps as arrows may not be visible. The differential bearing caps must be installed in their identical locations and positions.

NOTE: Apply pressure toward the LH side to make sure the LH differential bearing cap is seated.

Install the LH differential bearing cap and loosely install the differential bearing cap bolts.





4. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected can be installed by hand.





5. Install the RH side differential bearing cap and tighten the LH side and RH side differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).





6. Rotate the differential assembly to make sure it rotates freely.






7. NOTE: If ring gear backlash is within specification, go to Step 12.

NOTE: Specification shown is the maximum ring gear backlash allowable.

Using the special tools, measure ring gear backlash.
^ Turn the ring gear without turning the pinion gear and record the measurement.












8. NOTE: The differential bearing caps must be removed before differential bearing shims can be installed.

To increase ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.
^ If ring gear backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.






9. NOTE: The bearing caps must be removed before differential bearing shims can be installed.

To decrease ring gear backlash, install a thicker differential bearing shim (1) and a thinner differential bearing shim (2) as shown.





10. Rotate the differential assembly several times to make sure the differential bearings are seated.






11. NOTE: Specification shown is the maximum ring gear backlash variation between measurements allowed.

Using the special tools, recheck the ring gear backlash.





12. Remove the differential bearing cap bolts (1) and differential bearing caps (2).






13. NOTE: To establish differential bearing preload, increase both left and right differential bearing shim sizes as shown. Make sure differential bearing shims are fully seated and the differential assembly turns freely.

Using the special tool, install the differential bearing shims.





14. Install the differential bearing caps and differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).






15. NOTE: Specification shown is the maximum ring gear backlash variation between measurements allowed.

Using the special tools, recheck the backlash.
16. Install the axle shafts.