Differential: Service and Repair

DISASSEMBLY
1. Use a punch to remove the pinion shaft roll pin.

NOTE: Do not remove the final drive pinion shaft retaining ring.





2. Remove the differential pinion shaft.





3. Remove the differential pinion gears and differential pinion thrust washers.

Differential Side Gears & Thrust Washers:

4. Remove the differential side gears and differential side gear thrust washers.
5. Clean all parts thoroughly in clean solvent and blow dry with moisture-free compressed air.
6. Inspect the differential parts for damage and wear:
^ gear teeth
^ thrust washer surface
^ thrust bearing surface
^ pinion shaft





7. Inspect the final drive planet and carrier:
^ pinion gear teeth
^ pinion gear bearings
^ thrust bearing surfaces
^ bushing surfaces

Final Drive Planet And Carrier Pinion Gear Endplay Inspection:

8. Inspect the final drive planet and carrier pinion gear end play. End play should be between 0.17 to 0.65 mm (0.006 to 0.025 inch).





ASSEMBLY
1. Install the differential side gears and differential side gear thrust washers.
2. Install the differential pinion gears and differential side gear thrust washers.
3. Install the differential pinion shaft.





4. Install the pinion shaft roll pin.