19. Differential Assemble Overhaul

REMOVAL PROCEDURE
- Tools Required
- J28509-A Side Bearing Puller
- J 34851 Puller Adapter





1. Using a J 28509-A with a J 34851, remove the LH differential side bearing (7055) from the differential carrier.





2. Using a J 28509-A with a J 34851, remove the speedometer drive gear (7057) and the RH differential side bearing (7055) from the differential carrier.





3. Using a drift punch remove the pinion shaft roll pin (7059) from the differential carrier (7052).
Remove the following parts from the differential carrier (7052):
- Pinion shaft
- Pinion gears
- Side gears
- Ring gear retaining bolts
- Ring gear

4. Clean all parts thoroughly with solvent. Air dry.
5. Inspect the following parts:
- Gear teeth, for signs of damage and excessive or uneven wear
- Pinion gear washers and side gear washers, for signs of excessive wear, distortion or damage

INSTALLATION PROCEDURE
- Tools Required
- J 34842 Bearing Installer
- J 34851 Puller Adapter
- J 7079-2 Driver Handle
- J 8001 Dial Indicator Set





1. Install the following parts to the differential carrier (7052):
- The side gear washers and the side gears.
- The pinion gear washers and the pinion gears.
- The pinion gear shaft and the pinion shaft roll pin.
- The ring gear (7053) and the eight retaining bolts (7054).
- Tighten the ring gear retaining bolts to 90 Nm (65 ft. lbs.).





2. Using a J 34851 and a hydraulic press, identified in the illustration by the number 1, install the speedometer drive gear (7057). Place the gear on the press support and center the differential carrier (7052) and slowly press the differential carrier into the drive gear.





3. Using a J 34842 with a J 7079-2, install the differential side bearings (7055). With the seal side of the bearings facing the carrier, tap the bearings onto the carrier evenly.





4. Using a J 8001 measure the left differential side gear end play. Place the J8001 plunger between the teeth of the left differential side gear and move the left differential side gear up and down using two screwdrivers. Observe the J 8001.
5. Standard left differential side gear end play should be between 0.05 to 0.33 mm (0.002 to 0.013 inch). If the left differential side gear end play falls below 0.05 mm (0.002 inch), replace the left side gear selective shim with the appropriate selective shim in order to obtain proper left differential side gear end play. Refer to Side Gear Selective Shim Specifications Side Gear Selective Shims Table under Specifications/Mechanical.





6. Using a J 8001 measure the right differential side gear end play. Place the J 8001 plunger on the rear of the right differential side gear and gently move the right differential side gear up and down using the fingertips of both hands. Observe the J 8001.
7. Standard right differential side gear end play should be between 0.05 to 0.33 mm (0.002 to 0.013 inch). If the right differential side gear end play falls below 0.05 mm (0.002 inch), replace the right side gear selective shim with the appropriate selective shim in order to obtain proper left differential side gear end play. Refer to Side Gear Selective Shim Specifications Side Gear Selective Shims Table under Specifications/Mechanical.