Differential: Service and Repair

DISASSEMBLY

NOTE: Whenever a differential bearing is removed, a new differential bearing must be installed.

1. Remove the roll pin.
2. Remove the differential pinion shaft.





3. Remove the differential pinion gears and differential pinion thrust washers by rotating them out of the differential.
4. Remove the differential side gears and differential side gear thrust washers.





5. Use Gear and Pulley, Pull D80L-522-A Step Plate Adapter D80L-630-3 (part of D80L-630-A), Bearing Pulling Attachment D84L-1123-A, and the Legs from Push-Pull Set D80L-927-A or equivalents to remove the rear differential bearing (speedometer drive gear end).
6. Remove the speedometer drive gear.





7. Use Differential Bearing Cone Remover/Replace T77F-4220-B3 and Step Plate Adapter D80L-630-3 (part of D80L-630-A) or equivalent to remove the front differential bearing (ring gear end).
8. Clean and inspect differential, perform backlash check as follows:

INSPECTION
Check the differential case for:
- Damaged or worn gears.
- Cracked or damaged gear case.





Backlash
Check the side gear and pinion backlash using the following procedure:
a. Install the LH front wheel driveshaft and joint and RH front wheel driveshaft and joint into the differential.
b. Support the front wheel driveshaft and joints on V-blocks.
c. Use Dial Indicator With Bracketry T50T-4201-C or equivalent to measure the backlash of both pinion gears.
d. If the backlash is more than allowable, select a thrust washer with a different thickness.

Backlash: 0.050-0.150 mm (0.0020-0.0059 inch)





ASSEMBLY
1. Use either Driver Handle T80T-4000-W or a press, and Differential Bearing Cone Replace T88C-77000-EH to install the speedometer drive gear and rear differential bearing.





2. Use either Driver Handle T80T-4000-W or a press, and Differential Bearing Cone Replace T88C-77000-EH and install the front differential bearing (ring gear end).
3. Install the differential pinion thrust washers and differential pinion gears.
4. Install the differential pinion shaft.
5. Install the roll pin, then crimp it so it cannot come out of the gear case.
6. Install the differential side gear thrust washer and differential side gears.