Differential Replacement

Differential Replacement

Tools Required
* J 24429 Side Bearing Backlash Spanner
* J-38125 Terminal Repair Kit

Removal Procedure

Important: Group and mark the shims together as originally removed. If you remove or replace the ring gear and drive pinion, the differential side bearing preload, backlash, and gear tooth contact pattern check procedures must be performed in order to ensure proper contact of the gears. If you re-install or replace the differential assembly without replacing any other component (i.e. drive pinion and ring gear, differential side bearings, etc.) then you may re-install the differential assembly with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the differential assembly.

1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the tires and wheel assemblies.
3. Remove the brake calipers.
4. Remove the rear axle housing cover and the gasket.
5. Remove the axle shafts.
6. Disconnect the electronic locking differential coil harness connector.




7. Remove the positive terminal lock reinforcer using the J 38125-552.




8. Disconnect the terminals from the electronic locking differential coil connector by pushing on the terminal release tabs within the connector housing using the J 38125-12A.




9. Remove the electronic locking differential coil connector housing.




10. Remove the right side differential bearing adjuster nut lock.




11. Remove the locking differential coil assembly lock bolt.
Do nut reuse the bolt.
12. Remove the locking differential coil assembly lock.




13. Remove the left side differential bearing bolts.
14. Remove the left side differential bearing cap.




15. Remove the locking differential coil assembly wiring from the axle housing.





Caution: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.

16. Remove the right side differential bearing cap bolts.
17. Remove the right side differential bearing cap.
18. Loosen the differential bearing adjuster nut using the J 24429.





Notice: When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.

19. Remove the differential assembly.
20. Remove the shim and the differential side bearing cups.
Mark the differential side bearing cups left and right. Place the differential side bearing cups with the differential bearing caps.
21. Remove the differential side bearings, if necessary.
22. Remove the ring gear, if necessary.

Installation Procedure

1. Install the ring gear, if necessary.
2. Install the differential side bearings, if necessary.
3. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations.




4. Install the differential assembly into the axle housing by performing the following steps:

* Position the locking differential coil assembly wiring harness towards the rear axle housing cover, parallel to the drive pinion.
* Place the case, with the bearing cups installed, into the axle housing.
Support the case in order to keep the case from falling out of the axle housing.
* If the differential assembly cannot be installed, turn the differential side bearing adjuster nut into the axle housing until the differential assembly can be installed.
* Route the wiring of the locking differential coil assembly away from the left side differential bearing cap mounting surface.




5. Install the bearing caps and the bolts.
Do not torque the bearing cap bolts at this time.
6. Adjust the differential side bearing preload. Refer to Differential Side Bearing Preload Adjustment.
7. Adjust the backlash.
8. Once backlash and bearing preload is correct, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to Gear Tooth Contact Pattern Inspection.




9. Remove the left side bearing cap bolts.
10. Remove the left side bearing cap.
11. Rotate the locking differential coil assembly wiring harness towards the top of the axle housing in order to align the locking differential coil assembly lock tab with the top of the differential bearing cap.




12. Install the locking differential coil assembly wiring through the axle housing opening.
Push the wiring grommet through the axle housing opening until fully seated.




13. Install the left side differential bearing cap.
Route the locking differential coil assembly wires around the differential bearing cap.
14. Install the left side differential bearing cap bolts.

Notice: Refer to Fastener Notice.

15. Tighten the bearing cap bolts.

Tighten the bearing cap bolts to 85 N.m (63 lb ft).

16. Install the locking differential coil assembly lock.




17. Install the new locking differential coil assembly lock bolt.

Tighten the locking differential coil assembly lock bolt to 26 N.m (19 lb ft).




18. Install the right side differential bearing adjuster nut lock.
19. Install the differential bearing adjuster nut lock bolt.

Tighten the differential bearing adjuster nut lock bolt to 26 N.m (19 lb ft).




20. Install the locking differential coil assembly wires to the locking differential coil connector.




21. Install the positive terminal lock reinforcer.
22. Connect the locking differential coil connector to the wire harness.
23. Install the axle shafts.
24. Install the rear axle housing cover and a new gasket..
25. Install the brake calipers.
26. Install the tire and wheel assemblies.
27. Fill the axle with lubricant. Use the proper fluid. Refer to Lubricant Replacement - Rear Drive Axle.
28. Lower the vehicle.