Differential Case and Ring Gear
Differential Case and Ring GearSpecial Tool(s):
Material:
Disassembly
1. Remove the differential carrier.
2. Remove the 10 differential ring gear bolts.
3. CAUTION: Care should be taken not to damage the differential ring gear bolt hole threads.
Insert a punch in the differential ring gear bolt holes and drive the differential ring gear off.
4. Using the special tools, remove the differential bearings.
5. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft.
^ Discard the differential pinion shaft lock bolt.
6. WARNING: Due to the spring tension, care must be used when removing the differential clutch spring.
Remove the differential clutch spring.
7. Remove the differential gears.
1 Remove the differential pinion gear and thrust washers.
2 Remove the 2 differential side gears.
8. CAUTION: Keep the differential clutch packs in order. Do not mix the differential clutch packs. The differential clutch packs must be reassembled in the same sequence.
Remove the differential clutch packs and differential side gears and tag them RH and LH with the selective shim.
^ Clean and inspect the remaining components of the differential case for wear or damage and install new components as necessary.
9. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only.
Clean and inspect the differential clutch packs for wear or damage and install new components as necessary.
Assembly
1. Prelubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.
2. CAUTION: Do not mix the differential clutch packs or selective shims from one side with the other.
Assemble the differential clutch packs (without the selective shims) on the respective differential side gears.
3. CAUTION: Make sure the correct mandrel is used with the special tool.
Place the base portion of the special tool in a vise. Install the differential clutch pack and differential side gear (without the selective shim) on the gauge.
4. Position the special tool hand-tight on top of the differential clutch pack.
5. Install the special tool over the disc and differential clutch pack.
6. Install the nut of the gauge over the top and base stud.
^ Tighten to 6.7 Nm (60 inch lbs.).
7. NOTE: Selective shims shown are available as part of the Clutch Pack Replacement Kit 3L1Z-4947-BD.
Use the feeler gauge and select the thickest blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new selective shim.
Selective Shims:
8. Remove the special tool from the clutch pack and differential side gear assembly.
9. Install selective shims on the clutch pack and differential side gear assembly.
10. Install the differential side gear in the differential case.
11. Install the differential pinion gears with differential pinion gear thrust washers in the differential case.
12. Using a soft-faced hammer, install the differential clutch spring.
13. NOTE: If a new differential pinion shaft lock bolt is unavailable, coat the threads of the old differential pinion shaft lock bolt with Threadlock and Sealer.
Install the differential pinion shaft and Install a new differential pinion shaft lock bolt finger-tight.
14. Using the special tool, install the differential bearings on the differential case.
1 Position the differential bearing.
2 Using the special tool, press on the differential bearing.
15. Press the differential ring gear on the differential assembly.
16. Apply Stud and Bearing Mount to the differential ring gear bolts and install the differential ring gear bolts.
^ Tighten to 105 Nm (77 ft. lbs.).
17. Check the torque required to rotate one differential side gear.
^ Mount the differential assembly and special tool in a vise.
^ The initial minimum break-away torque, if original clutch plates are used, must be within specification. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary.
18. Install the differential carrier.