Differential Case

Differential Case









8.8-Inch Axle













Removal

1. WARNING: If equipped with fire suppression system, refer to Fire Suppression System for Important Safety Warnings. Failure to follow this instruction may result in serious personal injury Procedures.
Remove the axle shafts. For additional information, refer to Axle Shaft Service and Repair.

2. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.

3. Rotate the differential assembly to check for roughness indicating bearing/gear damage.

4. Using a Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure and record the differential ring gear backlash between the teeth in 4 opposing places.





5. NOTE: Mark the position of the differential bearing caps, as the arrows may not be visible. Always install the bearing caps in their original locations and positions.
Remove the 2 differential bearing caps.

1. Remove the 4 bolts.

2. Remove the differential bearing caps.





6. NOTICE: Do not allow the differential assembly to fall or component damage may occur.

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

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





7. Remove the 10 differential ring gear bolts.





8. NOTE: Do not damage the differential ring gear bolt hole threads.

Insert a punch in the bolt holes, and drive off the differential ring gear.





9. If the differential ring gear backlash variation between teeth measurement, taken at the beginning of this procedure, exceeded the specification, the cause may be a warped differential ring gear or differential case/differential bearing damage. Proceed as follows to verify the cause of the excessive backlash.

10. NOTE: Visually inspect the differential bearing cups and cones for discoloration indicating bearing overheating or failure.

Position the differential assembly, including the differential bearing cups and differential bearing shims as removed, in the differential housing. Install the differential bearing caps and the bolts.

- Tighten to 114 Nm (84 lb-ft).





11. Install the Dial Indicator Gauge with Holding Fixture.

1. Rotate the differential case to verify that the differential bearings have seated correctly.

2. Position the Dial Indicator Gauge with Holding Fixture.

- Make sure there is no differential case endplay.





12. Measure and note the differential case runout.

1. Install the differential shims and bearing caps.
- Rotate the differential to seat the differential bearings

2. Install the Dial Indicator Gauge with Holding Fixture and record the case runout.

- If the runout does not exceed the specification, install a new differential ring gear and pinion. For additional information, refer to Differential Ring And Pinion Differential Ring and Pinion.

- If the runout exceeds the specification, the concern is due to differential case/differential bearing damage. Install a new differential case. For additional information, refer to Differential Case and Ring Gear - Conventional Differential Case and Ring Gear - Conventional or Differential Case and Ring Gear - Traction-Lok(R) Differential Case and Ring Gear - Traction-Lok(R).





13. Using the 2-Jaw Puller and Step Plate, remove the differential bearings.





Installation

All vehicles

1. Using the Differential Side Bearing Installer, install the new differential bearings.

1. Position the bearings.

2. Using the Differential Side Bearing Installer, press the bearings on the differential case.





2. Position the differential ring gear and the differential case. Align the bolt holes by starting 2 bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.





3. NOTE: Clean the threads of the ring gear bolts. Make sure they are free of foreign material.

NOTE: Apply stud and bearing mount to the bolt threads.

Install the 10 bolts.

- Tighten to 114 Nm (84 lb-ft).





4. With the pinion depth set and pinion installed, place the differential assembly in the differential housing.





5. Install a differential bearing shim on the left side.





6. NOTICE: Always install the differential bearing caps in their original locations and positions or damage to the component may occur.

NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats correctly.

Install the left differential bearing cap and loosely install the 2 bolts.





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





8. Install the right side differential bearing cap and tighten the 2 left side and 2 right side bolts.
- Tighten to 114 Nm (84 lb-ft).





9. Rotate the differential case to make sure it turns freely.

Measuring backlash

10. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure and note the differential ring gear backlash.
- If backlash is within the specification, refer to Backlash within specification in this procedure.

- If a zero backlash condition occurs, refer to Zero backlash in this procedure.

- If backlash is not within the specification, refer to Backlash not within specification in this procedure.










Zero backlash

11. If a zero backlash condition occurs, add 0.51 mm (0.020 in) to the RH side and subtract 0.51 mm (0.020 in) from the LH side to allow backlash indication. Measure the backlash. For additional information, refer to Measuring backlash in this procedure.





Backlash not within specification

12. To increase or decrease backlash, remove the differential bearing caps and install a thicker shim and a thinner shim accordingly.
- If backlash is not within the specification, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount.





13. Rotate the differential assembly several times to verify that the differential bearings seated correctly.

14. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the backlash.
- If backlash is within the specification, refer to Backlash within specification in this procedure. If backlash is not within the specification, repeat Backlash not within specification in this procedure.





Backlash within specification

15. Remove the 4 bolts and the differential bearing caps.

16. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown.





17. Using the Differential Shim Installer, fully seat the differential bearing shims. Make sure the assembly rotates freely.





18. Install the 2 differential bearing caps and 4 bolts.
- Tighten to 114 Nm (84 lb-ft).





19. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the backlash.





20. Install the axle shafts. For additional information, refer to Axle Shaft Service and Repair.

21. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System. Failure to follow these instructions may result in serious personal injury Procedures.
Repower the system.