Differential: Service and Repair

DISASSEMBLE

Removing Differential Bearings:

1. Remove left and right differential bearings using tools shown in the Removing Differential Bearings image, or equivalent.
2. Remove speedometer drive gear, then the differential side gears by rotating gears toward case window.
3. Drive out pinion shaft retaining pin using a 5/32 inch punch.
4. Remove pinion shaft, pinion gears, and thrust washer.
5. If inspection indicates a need for final drive gear replacement, proceed as follows:

Removing Drive Gear Rivets:

a. Remove rivets using a 5/16 inch drill, avoiding distortion of case by drilling on the performed side of the rivets.
b. After drilling, remove head of the rivet using a chisel.
c. Using a punch, drive out the remaining shank.

ASSEMBLE
1. Lubricate thrust washer, thrust surfaces on gears, and differential case with automatic transmission fluid.
2. If removed, align and press final drive gear onto the differential case.

Installing Drive Gear Attaching Bolts:

3. Install gear attaching bolts as shown in the Installing Drive Gear Attaching Bolts image.
4. Use only nuts and bolts supplied for service and torque them.
5. Install speedometer drive gear, ensuring gear is installed with bevel on the inside diameter facing the differential case.

Installing Differential Ball Bearings:

6. Install differential ball bearing using differential bearing installation tool No. T83P-4220-BH or equivalent.