Overhaul
Differential Case and Ring Gear
Disassembly
1. Remove the differential carrier. For additional information, refer to Differential Carrier Differential Carrier.
2. Remove and discard the 10 differential ring gear bolts.
3. NOTE: 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. NOTE: The differential flange and ring gear flange must be free of any old retaining compound. Failure to clean the surfaces can result in ring gear runout concerns.
Clean all traces of the old retaining compound from the differential flange and the ring gear flange.
- Use solvent and Scotch-Brite(R) pads to remove old material.
5. Using a 2 Jaw Puller and Step Plate, remove the 2 differential bearings.
6. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft.
- Discard the differential pinion shaft lock bolt.
7. NOTE: Due to the spring tension, care must be used when removing the differential clutch spring.
Remove the differential clutch spring.
8. Remove the differential gears.
1. Remove the 2 differential pinion gears and 2 thrust washers.
2. Remove the 2 differential side gears.
9. NOTE: 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.
Assembly
1. Using friction modifier, separate the plates and lubricate each steel clutch plate. Soak all the friction plates for no less than 15 minutes.
2. NOTE: Do not mix the clutch plates, clutch discs or shim from one side with the other.
Assemble the differential clutch packs on their respective differential side gear.
3. Place the base portion of the Differential Clutch Gauge in a vise. Install the differential side gear and differential clutch pack (without the shim) on the tool.
4. Position the Differential Clutch Gauge hand-tight on top of the differential clutch pack.
5. Install the Differential Clutch Gauge over the disc and differential clutch pack.
6. Install the nut.
- Tighten to 6.7 Nm (60 lb-in).
7. Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim.
Selective Shims
8. Remove the Differential Clutch Gauge from the differential clutch pack and differential side gear assembly.
9. Install the shim(s) on the differential clutch pack and differential side gear assembly.
10. Install the 2 differential side gear assemblies in the differential case.
11. Install the 2 differential pinion gear and differential pinion thrust washer assemblies in the differential case.
12. Using a soft-faced hammer, install the differential clutch spring.
13. Install the differential pinion shaft and install a new bolt finger-tight without tightening into the loctite covered area of the bolt.
14. Using the Differential Side Bearing Installer, install the 2 differential bearings.
15. Apply a one-eighth inch bead of maximum strength retaining compound on the rear face of the ring gear in the pattern shown.
16. Position the differential ring gear and the differential case. Align the bolt holes by starting 2 new bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.
17. Install the 10 new differential ring gear bolts.
- Tighten to 135 Nm (100 lb-ft).
18. Using the Differential Clutch Gauge, check the torque required to rotate one differential side gear.
- Mount the differential assembly and Differential Clutch Gauge 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.
19. Install the differential carrier. For additional information, refer to Differential Carrier Differential Carrier.