Differential Disassembly and Reassembly

DISASSEMBLY








1. Remove differential bearing cone.





2. Remove ring gear bolts and ring gear.
3. Pry the speedometer drive gear off of the differential case using a flat blade pry tool.

NOTE: The speedometer drive gear must be remove from the differential case in order to service the differential gears.





4. Remove pinion shaft solid pin.





5. Remove pinion shaft.





6. Rotate side gears to opening in differential.
7. Remove pinion gears, side gears and thrust washers by rotating side gears to opening in case.





8. Pry the plastic speedometer drive gear off of the differential case using a flat blade pry tool.

REASSEMBLY





1. Position speedometer drive gear onto differential assembly.





2. Using MB995065 and steel stock, press speedometer drive gear onto differential. Do not use a hammer.





3. Assemble the differential side gears and pinion gears with the pinion gears washers.





4. Install pinion shaft.





5. Stake pinion shaft solid pin with a suitable chisel.
6. Rotate the assembly two full revolutions both clockwise and counterclockwise.





7. Set up dial indicator as shown and record end play.
8. Rotate side gear 90 degrees and record another end play.
9. Again, rotate side gear 90 degrees and record a final end play.





10. Using the smallest end play record, shim that side gear to within 0.25 mm (0.001 inch) to 0.33 mm (0.013 inch).
11. The other side gear should be checked using the same procedure.

NOTE: Side gear end play must be within 0.25 mm (0.001 inch) to 0.33 mm (0.013 inch). Five select thrust washers are available:
0.69 mm (0.027 inch), 0.81 mm (0.032 inch), 0.94 mm (0.037 inch), 1.07 mm (0.042 inch) and 1.19 mm (0.047 inch).

12. After the end play is measured and adjusted, replace speedometer drive gear with a new one.
13. Install drive gear lip downward.








14. Install differential bearing cone.