S. Differential Assembly

REMOVE OR DISCONNECT

- Tools Required:
- J 35378 Intermediate Shaft Installation Pilot
- J 22888-D Side Bearing Remover

1. Place an index mark (reference mark) on the differential ring gear and differential carrier to ensure the differential ring gear is installed in the same position from which it was removed.
2. Place the differential assembly in a soft jaw vise.





3. Unstake the lock tabs on the differential ring gear bolts.





4. Eight differential ring gear bolts and lock tabs from differential ring gear.





5. Differential carrier from ring gear using a J 35378 and a hammer.





6. Left differential side bearing using a J 22888-D with a J 35378.





7. Right differential side bearing using a J 22888-D with a J 35378.





8. Speedometer drive gear from differential carrier.





9. Pinion shaft roll pin from pinion shaft using a standard drift punch and a hammer.





10. Pinion shaft, two pinion gears, two pinion gear thrust washers, two side gears and two side gear selective thrust washers from differential carrier.

Clean
- All differential assembly components and dry thoroughly.

Inspect
1. Differential ring gear for chipped or cracked teeth, excessive wear or other damage. Replace as necessary.
2. Side gears and pinion gears for excessive wear or damage. Replace as necessary.
3. Differential carrier bores and bearing surfaces for excessive wear or damage. Replace as necessary.
4. Differential side bearings.

Measure

- Tool Required:
- J 7872 Magnetic Base Indicator Set

- Differential side gear backlash using a J 7872.





A. Install the left differential side gear thrust washer, both pinion gears with their thrust washers and the pinion shaft into the differential carrier.





B. Place the plunger of the J 7872 on one of the pinion gear teeth. Wedge a screwdriver between the side gear and pinion shaft to prevent the side gear from turning.





C. Move the pinion gear on which the J 7872 plunger rests back and forth while observing the J 7872.





D. Repeat this process with the opposite pinion gear.

- Standard differential side gear backlash should fall within 0.05 to 0.20 mm (0.002 to 0.008 inch). If differential side gear backlash exceeds 0.20 mm (0.008 inch), replace the side gear selective thrust washers with the appropriate size selective thrust washers to bring differential side gear backlash within specification.

INSTALL OR CONNECT

- Tools Required:
- J 35409 Differential Side Bearing Installer
- J 35378 Intermediate Shaft Bearing Installation Pilot





1. Two side gear selective thrust washers, two side gears, two pinion gear thrust washers, two pinion gears and pinion shaft into differential carrier.
2. Pinion shaft roll pin into pinion shaft using a standard drift punch and a hammer.
3. Speedometer drive gear onto differential carrier.





4. Right differential side bearing using a hydraulic press, a J 35409 with a J 35378 for support.
5. Left differential side bearing using a hydraulic press, a J 35409 with a J 35378 for support.
6. Differential ring gear onto differential carrier aligning reference marks made during disassembly.
7. Four differential ring gear bolt lock tabs and eight differential ring gear bolts into differential ring gear.
- Tighten differential ring gear bolts to 97 Nm (72 ft. lbs.).
8. Stake the lock tabs on the differential ring gear bolts.
9. Remove the differential assembly from soft jaw vise.