Overhaul
NOTICE: Do not remove side bearings unless necessary.
DISASSEMBLY
NOTE: Disassemble in the order shown.
Roll Pin
NOTICE:
- Use protective plates in the vise to prevent damage to the differential.
- Insert the punch into the roll pin hole from the ring gear side.
1. Place the gear case on a vise and knock the pin out with a suitable pin punch and hammer.
Side Bearing Inner Race
1. Remove the side bearing inner race (side opposite ring gear) from the gear case with the SST (or equivalent).
2. Remove the side bearing (ring gear side) from the gear case with the SST (or equivalent).
INSPECTION
1. Inspect all parts and repair or replace as necessary.
ASSEMBLY
NOTE: Assemble in the reverse order of disassembly.
1. Set the speedometer drive gear onto the ring gear and case assembly.
NOTICE: Do not reuse the side bearings if they were removed.
2. Install new side bearings.
A. Press the side bearing (side opposite ring gear) into the ring gear and case assembly with the SST (or equivalent).
B. Press on the other side bearing (ring gear side) in the same manner.
3. Install the pinion gears and thrust washers into the case.
4. Install the pinion shaft.
5. Install the roll pin, and stake the hole it to prevent the roll pin from coming out of the gear case.
6. Install the thrust washers and side gears into the gear case at the same time, then rotate them around the pinion gears and align them with the driveshaft holes.
NOTICE: Be certain that both side gears are centered in their respective driveshaft holes. If not, remove both side gears and re-install them again.
7. Measure the backlash of the side gears and pinion gears as follows:
A. Install the left and right driveshafts in the differential assembly.
B. Support the driveshafts on V-blocks.
C. Measure the backlash of both pinion gears.
Standard Backlash: 0.001-0.004 inch (0.025-0.1 mm)
Maximum: 0.020 inch (0.5 mm)
8. If the backlash is not within specification, replace the differential assembly.
NOTE: Measure the backlash after assembly.