Differential Carrier Assembly - Disassemble
Differential Carrier Assembly - DisassembleInspection Procedure
Perform the following before disassembling the axle:
1. Remove the drain plug from the axle.
2. Drain the axle lubricant.
3. Inspect the oil and the case for metal chips. Determine the source of the metal chips, such as a broken gear or bearing cage.
4. 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
Tools Required
^ J21551 Output Shaft Bearing Remover
^ J22912-01 Pinion Bearing Remover
^ J23907 Slide Hammer
^ J29369-1 Bushing/Bearing Remover
^ J29369-2 Bushing/Bearing Remover (2-3 inches)
^ J33791 Bushing Remover and Installer Set
^ J33792 Side Bearing Adjuster Socket
^ J33837 Pinion Bearing Cup Remover and Installer
^ J34011 Pilot Bearing Remover
^ J36611 Output Shaft Bearing Remover
^ J42213 Side Bearing Adjuster Socket
^ J8092 Driver Handle
^ J8614-01 Pinion Flange Holder
1. Remove the 2 remaining inner axle shaft housing bolts.
2. Remove the inner axle shaft housing with the inner axle shaft.
3. Remove the following components from the inner axle shaft housing:
3.1. The clutch cable retainer spring
3.2. The clutch fork assembly
3.3. The clutch fork inner spring
3.4. The clutch fork sleeve
3.5. The thrust washer
3.6. The clutch gear by doing the following:
3.6.1. Clamp the inner shaft housing in a vise. Clamp only on the mounting flange.
3.6.2. Strike the inside surface of the axle shaft with a hammer and a brass drift in order to dislodge the front drive axle clutch gear from the inner axle shaft.
3.6.3. Remove the front drive axle clutch gear.
3.7. Remove the thrust washer.
4. Remove the inner axle shaft.
5. Remove the clutch fork seal. Use a punch to drive out the seal.
6. Remove the inner axle shaft seal and the bearing by doing the following:
6.1. Install the J23907(1) and the J29369-1 (2) as shown.
6.2. Remove the inner axle shaft seal and the bearing by pulling on the J23907(1).
7. Remove the front drive axle clutch shaft.
8. Remove the thrust washer from the right side differential carrier assembly case half.
9. Remove the clutch shaft bearing using the J3401 1.
10. Remove the inner axle shaft seal cover and the seal.
11. Remove the inner axle shaft seal by doing the following:
11.1. Install the inner axle shaft seal cover in a vise.
11.2. Install the J29369-1 to the backside of the inner axle shaft seal.
11.3. Install the J23907to the J29369-1.
11.4. Remove the inner axle shaft seal by pulling on the J23907.
12. Remove the differential carrier assembly bolts.
13. Separate the left carrier case half from the right carrier case half by inserting a screwdriver into the slots provided and prying the case apart.
14. Remove the differential case assembly.
15. Remove the differential bearing adjuster nut lock bolts and the differential bearing adjuster nut locks.
16. Remove the left differential bearing adjuster and the differential case bearing cup by doing the following:
16.1. Install the J42213 onto the differential bearing adjuster nut.
16.2. Turn the J42213 clockwise in order to remove the differential bearing adjuster and the differential case bearing cup out of the bore.
17. Remove the right differential bearing adjuster and the differential case bearing cup by doing the following:
17.1. Install the J33792 Onto the differential bearing adjuster nut.
17.2. Turn the J33792 clockwise in order to remove the differential bearing adjuster and the differential case bearing cup out of the bore.
18. Remove the left inner shaft bearing using the J36611 (2) and the J8092 (1).
19. Remove the right inner shaft bearing using the J21551(2) and the J8092(1).
20. Install the J8614-01 as shown. Remove the pinion nut while holding the J8614-01.
21. Remove the washer.
22. Install the J8614-2 (2) and the J8614-3 (3) into the J8614-01 (1) as shown.
23. Remove the pinion yoke by turning the J8614-3 (3) clockwise while holding the J8614-01 (1).
24. Remove the dust deflector from the pinion yoke by doing the following:
24.1. Tap the deflector off the pinion yoke.
24.2. Clean up the stake points on the pinion yoke.
25. Mount the left side differential carrier case in the J33837-1.
26. Install the J33837-3.
27. While holding the J33837-3, turn the nut sleeve of the J33837-1 counterclockwise to remove the following components:
^ The drive pinion
^ The drive pinion selectable shim
^ The inner pinion bearing
^ The collapsible spacer
28. Remove the collapsible spacer from the pinion.
29. Remove the inner pinion bearing by installing the J22912-01 between the pinion bearing and the pinion gear and pressing the bearing off the pinion.
30. Remove the pinion gear selectable shim.
31. Install the J33837-6 (2) onto the J33837-3 between the inner and the outer bearing cup.
32. While holding the J33837-3, turn the nut sleeve of the J33837-1 clockwise in order to remove the following components:
^ The pinion oil seal
^ The pinion outer bearing
^ The pinion outer bearing cup
33. Install the J33837-6 (2) onto the J33837-3 on the inside surface of the outer bearing cup.
34. While holding the J33837-3, turn the nut sleeve of the J33837-1 counterclockwise in order to press the inner pinion bearing cup out from the differential carrier case.
35. Install the J33791 onto the differential carrier assembly bushings.
36. Remove the bushings using the J33791.