Differential

Components

Backlash Inspection





1. Place the differential assembly on V-blocks, and install both axles.
2. Check the backlash of both side gears.
3. If the backlash is out of tolerance, replace the differential carrier.

Bearing Replacement

NOTE: Check the bearings for wear and rough rotation. If the bearings are OK, removal is not necessary.





1. Remove the tapered roller bearings using a bearing puller and a bearing separator as shown.





2. Install the new tapered roller bearings using the special tool and a press as shown.

NOTE:
- The bearing and outer race should be replaced as a set.
- Inspect and adjust the bearing preload whenever a bearing is replaced.
- Press the bearings on securely so there is no clearance between the bearings and the differential carrier.

Differential Carrier Replacement

1. Remove the final driven gear from the differential carrier.

NOTE: The final driven gear bolts have left-hand threads.

2. Install the final driven gear with the chamfered side on the inner bore facing the differential carrier,





3. Tighten the bolts to the specified torque in a criss-cross pattern.

Tapered Roller Bearing Preload Adjustment

NOTE: If the transmission housing, torque converter housing, differential carrier, tapered roller bearing, outer race, spacer ('98 - '99 models), or thrust shim were replaced, the bearing preload must be adjusted.

CAUTION:
- Do not heat the housing in excess of 212°F (100° C).
- Replace the tapered roller bearing when the outer race is to be replaced.
- Do not use a shim on the torque converter housing side.

1. Remove the bearing outer race, spacer ('98 - '99 models) and thrust shim from the transmission housing by heating the housing to about 212° F (100° C) with a heat gun.





NOTE: Let the transmission housing cool to room temperature before adjusting the bearing preload.








2. Select the 2.60 mm (1.102 inch) thrust shim from the middle of the table below.
3. Install the thrust shim and spacer ('98 - '99 models) in the transmission housing, then install the outer race using the special tools as shown.





NOTE:
- Install the outer race securely in the transmission housing.
- Check that there is no clearance between the outer race, shim, spacer ('98 - '99 models), and transmission housing.

4. With the mainshaft, countershaft, and secondary shaft removed, install the differential assembly, and torque the transmission housing bolts.





NOTE: Install the gasket when checking starting torque.

5. Rotate the differential assembly in both directions to seat the bearings.





6. Measure the starting torque of the differential assembly with the special tool and a torque wrench,

NOTE:
- Measure the starting torque at normal room temperature in both directions.
- Changing the shim to the next size will increase or decrease starting torque about 0.3 - 0.4 Nm (3 - 3 inch lbs.).
- To increase the starting torque, increase the thickness of the shim. To decrease the starting torque, decrease the thickness of the shim.