Differential Case Cleaning and Inspection

1. Clean the differential case components with solvent.

Caution: Wear safety glasses in order to avoid eye damage.

2. Dry the components with compressed air.
3. Inspect the differential case for the following:
^ Cracks or other damage
^ Damage to threaded bolt holes
^ Unusual wear, scoring, or grooves in the clutch pack area
^ Scored or damaged differential case side bearing mounting flanges

Gears and Shafts





1. Clean the gears and shafts with solvent.
2. The ring gear and pinion must be inspected for a proper wear pattern.
^ The end of the gear tooth farthest away from the center of the ring gear (1) is the "heel" end of the tooth.
^ The end of the gear tooth nearest the center of the ring gear (2) is the "toe" end of the tooth.
^ The side of the tooth that curves inward or is concave (3) is considered the "coast" side of the tooth.
^ The side of the tooth that curves outward or is convex (4) is considered the "drive" side of the tooth.





3. Inspect the gear teeth for improper wear.
Unusual wear on the heel (1) end of the coast tooth (4) or the toe end (2) of the drive tooth (3) may be caused by incorrect pinion depth.
The pinion gear is too far away from the ring gear.





4. Inspect the gear teeth for improper wear.
Unusual wear on the toe end (2) of the coast tooth (4) or the heel end (1) of the drive tooth (3) may be caused by incorrect pinion depth.
The pinion gear is too close to the ring gear.





5. A ring gear and pinion with the proper pinion depth and gear backlash will wear evenly and in the center of each tooth (3 and 4).





6. Inspect the gears for the following:
^ Chips or cracks
^ Pitting
^ Heat discoloration
^ Unusual wear
^ Excessive wear or scoring in the side gear (1)
^ pin bores
^ Wear, grooves, or scoring on the side gear pin
^ Scored or worn side gear washers (2)
^ Unusual wear or grooves on the output gear (3) splines
^ Damaged to the ring gear threaded bolt holes
^ Damage to the ring gear vehicle speed sensor reluctor ring lobes





7. Inspect the shafts for the following:
^ Unusual wear
^ Grooved, worn, or damaged splines
^ Damaged C-clip grooves

Clutch Discs and Plates





1. Clean the discs and plates with solvent.
2. Inspect the discs and plates for the following:
^ Unusual wear, scoring, or grooves on the separator plate friction surfaces (1)
^ Friction plates with uneven wear or worn friction material (2 and 3)
If any one plate or disk in either the left or right pack show signs of wear or scoring replace the complete pack on both sides.
^ Bent or warped plates or discs
Lay the plates and discs on a flat surface and inspect for warpage
^ A worn, scored, or collapsed bellville washer (4)


Bearings and Races





1. Inspect the bearing rollers and races for the following:
^ Pitting
^ Scoring or grooves
^ Excessive wear or other damage





2. Inspect the bearing rollers and races for heat discoloration.
Heat discoloration ranges from a faint yellow to a dark blue color. This discoloration may result from an overload or improper lubrication. Excessive heat causes softening of the rollers and races. Bearings or races with sign of heat discoloration must be replaced.





3. Inspect for bent bearing cages.





4. Inspect for damaged bearing cages.





5. Inspect the left side cover output shaft bearing for worn or missing needle bearings.