Differential Carrier Assembly - Disassemble

Differential Carrier Assembly - Disassemble

^ Tools Required
^ J 22912-01 Split-Plate Bearing Remover
^ J 2619-01 Slide Hammer
^ J 29369-2 Bushing and Bearing Remover 2-3 in
^ J 36599-A Side Bearing Nut Wrench
^ J 36615 Side Bearing Nut Wrench
^ J 45754 Pinion Bearing Race Remover/Installer - 9.25 inch Axle
^ J 45755 Front Axle Bushing Remover/Installer
^ J 45765 Pinion Remover - 8.25 inch/9.25 inch Axles
^ J 8614-01 Flange and Pulley Holding Tool

Inspection Procedure
Perform the following before disassembling the axle:
1. Remove the fill plug from the axle.
2. Remove the drain plug from the axle.
3. Drain the axle lubricant.
4. Inspect the oil and the case for metal chips. Determine the source of the metal chips, such as a broken gear or bearing cage.
5. Check the ring gear backlash.
This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and preloading the differential case.
Determine the cause of the axle problem before disassembly, if possible.

Disassembly Procedure





1. Remove the inner axle shaft housing to differential carrier assembly bolts.





2. Remove the inner axle housing with the inner axle shaft.
3. Install the inner axle shaft housing into a vise.





4. Install the J 45755-2 (2), J 45755-1 (1), and the forcing screw, bearing and washers (3) over the inner shaft housing bushing as shown.
5. Remove the inner shaft housing bushing using the J 45755.
6. Remove the inner axle shaft from the inner axle housing using a hammer and brass drift.





7. Install the J 29369-2 behind the inner axle shaft seal.
8. Install the J 2619-01 (2) to the J 29369-2 (1).
9. Remove the inner axle shaft seal using the J 2619-01.





10. Install the J 29369-2 behind the inner axle shaft bearing.
11. Install the J 2619-01 (2) to the J 29369-2 (1).
12. Remove the inner axle shaft bearing using the J 2619-01.
13. Place the differential carrier assembly into a vise.Clamp only on the mounting flange of the differential carrier assembly case.





14. Remove the left side inner axle shaft using a hammer and a brass drift.





15. Install the J 29369-2 (2) behind the inner axle shaft seal.
16. Install the J 2619-01 (1) to the J 29369-2 (2).
17. Remove the inner axle shaft seal using the J 2619-01.





18. Install the J 29369-2 (2) behind the inner axle shaft bearing.
19. Install the J 2619-01 (1) to the J 29369-2 (2).
20. Remove the inner axle shaft bearing using the J 2619-01.





21. Remove the front differential carrier hole plug.





22. Remove the differential carrier assembly bolts.





23. Separate the left carrier case half from the right carrier case half by tapping on the on the carrier case lugs with a brass drift and a hammer.





24. Remove the differential case assembly.
25. Disconnect the right side differential bearing adjuster nut lock from the differential bearing adjuster nut by prying up on the lock.





26. Remove the differential bearing adjuster nut lock bolt from the differential bearing adjuster nut.





27. Remove the differential bearing adjuster nut lock from the differential bearing adjuster nut.





28. Remove the right side differential side bearing cup, the differential bearing adjuster nut, and the differential bearing adjuster sleeve by doing the following:
1. Install the J 36599-A onto the differential bearing adjuster nut.
2. Turn the J 36599-A clockwise in order to push the bearing cup out of the bore.
3. Remove the differential bearing adjuster sleeve using a hammer and a brass drift.





29. Remove the left side differential bearing adjuster by doing the following:
1. Install the J 36615 onto the differential bearing adjuster nut as shown.
2. Turn the J 36615 counterclockwise in order to remove the differential bearing adjuster nut, the O-ring seal and the differential side bearing cup.





30. Install the J 8614-01 as shown. Remove the pinion nut while holding the J 8614-01.
31. Remove the washer.





32. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
33. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).

34. Remove the pinion oil seal using a suitable seal removal tool.

Important: Carefully pry the seal from the bore. Do not distort or scratch the aluminum case.






35. Install the J 45765 to the left side differential carrier case half over the drive pinion as shown.
36. Turn the forcing screw of the J 45765 clockwise to remove the following components from the left side differential carrier case half:
^ The drive pinion gear
^ The pinion gear selectable shim
^ The inner pinion bearing
^ The collapsible spacer
37. Remove the collapsible spacer from the pinion.
38. Remove the outer pinion bearing from the differential carrier case half.





39. Remove the inner pinion bearing by installing the J 22912-01 between the pinion bearing and the pinion gear and pressing the bearing off the pinion.
40. Remove the pinion gear selectable shim.





41. Install the J 45754-3 over the inner pinion bearing cup.





42. Install the forcing screw (1) of the J 45754 into the J 45754-3 (2).
43. Drive out the inner pinion bearing cup by pounding on the forcing screw with a hammer.





44. Install the J 45754-2 (2) and the forcing screw (1) over the outer pinion bearing cup bore.





45. Install the J 45754-4 (3) into the pinion bearing bore behind the outer pinion bearing cup.Slowly turn the forcing screw (1) until the J 45754-4 is evenly seated behind the outer pinion bearing cup bore and the J 45754-2 (2) is evenly seated over the outer pinion bearing cup bore.
46. Remove the outer pinion bearing cup by turning the forcing screw clockwise.





47. Install the J 45755-3 (2), J 45755-4 (3), and the forcing screw, bearing and the washers (1) over the differential carrier assembly bushing as shown.
48. Remove the differential carrier assembly bushing using the J 45755.