Overhaul (Differential)

Component Location Index:

Component Location Index

Backlash Inspection





1. Install the driveshaft and intermediate shaft on the differential, then place the axles on V-blocks.
2. Check the backlash of the pinion gears (A) with a dial indicator (B).
Standard: 0.05 - 0.15 mm (0.002 - 0.006 inch)
3. If the backlash is out of standard, replace the differential carrier.

Differential Carrier/Final Driven Gear Replacement





1. Remove the final driven gear from the differential carrier, and replace the differential carrier or final driven gear. The final driven gear bolts have lefthand threads.
2. Install the final driven gear (A) in the direction shown on the differential carrier (B).

Carrier Bearing Replacement

Special Tools Required
Driver, 40 mm I.D. 07746-0030100





1. Remove the carrier bearing (A) with a commercially available puller (B) and shaft protector (C).





2. Install the bearing with the special tool and a press. Press the bearing on until it bottoms.

Oil Seal Replacement

Special Tools Required
^ Driver 07749-0010000
^ Driver attachment, 78 x 80 mm 07NAD-PX40100
^ Driver attachment, 58 mm 07JAD-PH80101





1. Remove the oil seal from the transmission housing.





2. Remove the oil seal from the flywheel housing.





3. Install the new oil seal flush with the transmission housing with the special tools.





4. Install the new oil seal flush with the flywheel housing with the special tools.

Carrier Bearing Side Clearance Inspection

Special Tools Required
Driver, 40 mm I.D. 07746-0030100





1. Install the set ring in the transmission housing.





2. Install the differential assembly in the transmission housing, then drive the differential to seat in the housing.





3. Install the three dowel pins (A) and new gasket (B) on the transmission housing (C).
4. Place the flywheel housing (D) on the transmission housing.
5. Install the housing bolts with the harness clamp bracket (E), and tighten them in a crisscross pattern in two or more steps.





6. Measure the clearance between the set ring and carrier bearing outer race with a feeler gauge.
Standard: 0 - 0.15 mm (0 - 0.006 inch)
7. If the clearance is out of standard, remove the set ring, and measure its thickness.





8. Select a new set ring from the following table.
9. Install the new set ring, and recheck the clearance and make sure it is within the standard.