Differential Replacement

Differential Replacement

Removal Procedure

Note: Group and mark the shims together as originally removed. If you remove or replace the ring and pinion gear set, perform the bearing preload, backlash, and gear tooth contact pattern check in order to ensure proper contact of the gears. If you reinstall or replace the differential carrier without replacing any other component (i.e. pinion and ring gear set, bearings. etc.) then you may reinstall the carrier with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the carrier.

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Remove the axle shafts. Refer to Rear Axle Shaft Replacement (Service and Repair).




Warning: Refer to Differential Case Removal Warning (Technician Safety Information).
3. Remove the bearing cap bolts.
4. Remove the bearing caps. Mark the bearing caps left and right.




5. For the 8.6 inch axle, install the pinion shaft into the differential case part way and rotate the differential assembly until the pinion shaft contact the top of the axle housing.

Caution: Refer to Differential Housing Cover and Gasket Removal Caution (Differential Housing Cover and Gasket Removal Caution).

6. For the 8.6 inch axle, rotate the drive pinion clockwise in order to force the differential assembly out of the axle housing.
7. Remove the differential assembly.
8. Remove the bearing cups, the shims, and the spacers as necessary.
Mark the cups and shims left and right and in the proper order as necessary. Place the cups and the shims with the bearing caps.
9. Remove the differential side bearings, if necessary. Refer to Differential Bearing Replacement (Differential Bearing Replacement).
10. Remove the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement (Rear Drive Axle).

Installation Procedure

1. Install the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement (Rear Drive Axle).
2. Install the differential side bearings, if necessary. Refer to Differential Bearing Replacement (Differential Bearing Replacement).
3. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (Maintenance).




4. Place the case, with the bearing cups installed, into the axle housing.
Support the case in order to keep the case from falling out of the axle housing.




5. Install the bearing caps and the bolts. Do not torque the bearing cap bolts at this time.
6. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment (Differential Carrier Bearing Preload Adjustment).
7. Adjust the backlash. Refer to Backlash Adjustment (Backlash Adjustment).
8. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection (Gear Tooth Contact Pattern Inspection).

Caution: Refer to Fastener Caution (Fastener Caution).

9. Tighten the bearing cap bolts.

For the 8.6 inch axle, tighten the bearing cap bolts to 75 Nm (55 lb ft)

10. Install the axle shafts. Refer to Rear Axle Shaft Replacement (Service and Repair).
11. Fill the axle with the proper lubricant. Refer to Differential Oil Replacement (Rear Drive Axle).
12. Lower the vehicle.