Front Drive Axle
Differential Case and Gears InspectionDifferential Case
1. Caution:
Refer to Safety Glasses Caution in Service Precautions.
Clean the differential case in solvent.
2. Inspect the differential case for the following conditions:
^ Chips or cracks
^ Damage to the bolts holes (1)
^ Unusual wear, grooves or scoring
^ Damaged side bearing flanges (2)
^ Heat discoloration
^ Worn differential pin bores (3)
3. Inspect the gears for the following conditions:
^ Pitting or heat discoloration
^ Unusual wear or scoring in the differential pin bores (2)
^ Unusual wear, loss of coating, grooves or scoring on the differential pin (3)
^ Scored or worn side gear washers (5) and pinion gear washers (1)
^ Unusual wear or grooves on the axle side gear splines (4)
4. Clean the pinion flange in solvent.
5. Inspect the pinion flange for the following conditions:
^ Splines for wear, pitting or twisting (1)
^ Sealing surface for grooves or pitting (2)
Bearings and Races
1. Inspect the bearing rollers and races for the following conditions:
^ Pitting
^ Scoring or grooves
^ Excessive wear or other damage
2. Inspect the bearing rollers and races for heat discoloration.Heat discoloration ranges from a faint yellow to a dark blue color. This discoloration may result from an overload or improper lubrication. Excessive heat causes softening of the rollers and races. Bearings or races with signs of heat discoloration must be replaced.
3. Inspect for damaged bearing cages.
4. Clean the differential carrier in solvent.
5. Clean and inspect for the following:
^ Pinion housing bolt hole threads (1)
^ Carrier cover bolt hole threads (2)
^ Carrier cover sealing area (3)
^ Drain plug threads (4)
^ Axle seal area (5)
6. Clean the oil passage between (1) and (2) in the axle bearing cup bore.
7. Inspect surfaces (1) and (2).
8. Ensure surfaces are clean and free of nicks or burrs.
9. Clean the differential cover in solvent.
10. Clean and inspect the following:
^ The oil passage between (1) and (2) in the axle cup bore
^ The fill plug threads (3)
^ The O-ring groove (4)
^ The cup and shim surfaces (5)
11. Inspect the cover axle seal mounting surface (1).
12. Caution:
Refer to Safety Glasses Caution in Service Precautions.
Important:
Only use this housing if old bearings are being used. New bearings, housing and spacer are a kit. The spacer is pre-cut and cannot be done in the field.
Clean the pinion bearing housing in solvent. Air dry by blowing out the oil holes behind the cups.
13. Ensure that there are no nicks or burrs on the mating surface (1) that would cause binding.
14. Clean the O-ring groove (2).