Differential Carrier Assembly -Disassemble
Differential Carrier Assembly -DisassembleInspection Procedure
Perform the following before disassembling the axle:
1. Remove the fill plug from the axle.
2. Remove the drain plug from the axle.
3. Drain the axle lubricant.
4. Inspect the oil and the case for metal chips. Determine the source of the metal chips, such as a broken gear or bearing cage.
5. Measure the rotating torque of the drive pinion and differential case assembly using an inch-pound torque wrench, if possible. Record the measurement.
6. Check the drive pinion to ring gear backlash, if possible.
This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and preloading the differential case.
Determine the cause of the axle problem before disassembly, if possible.
Disassembly Procedure
Tools Required
^ J22912-01 Pinion Bearing Remover
^ J02619-1 Slide Hammer
^ J29369-1 Bushing/Bearing Remover
^ J45224 Side Bearing Adjuster
^ J45232 Differential Bearing Adjuster Needle Bearing Installer - LH
^ J45228 Pinion Bearing Cup Remover/Installer
^ J45234 Pinion Remover - 7.25 in Axle
^ J45850 Front Axle Bushing Remover/Installer
^ J8092 Universal Driver Handle - 3/4 in - 10
^ J8614-01 Flange and Pulley Holding Tool
1. Remove the inner housing to differential carrier assembly bolts.
2. Remove the inner housing and inner shaft from the differential carrier assembly.
3. Remove the inner shaft.
4. Install the inner shaft housing into a vise.
5. Install the J29369-1 (2) and the J02619-1 (1) behind the inner shaft bearing.
6. Remove the inner shaft bearing and inner shaft seal using the J02619-1.
7. Install the J45850-2 (2), J45850-3 (1), the forcing screw, bearing, washers and nuts (1) over the upper inner shaft housing bushing as shown.
8. Remove the upper inner shaft housing bushing using the J45850.
9. Remove the inner shaft housing from the vise.
10. Install the inner shaft housing into a vise so that the lower inner shaft bushing bore is flush with the jaws of the vise.
11. Install the J45850-2 (2), J45850-3 (1), the forcing screw, bearing, washers and nuts (1) over the lower inner shaft housing bushing as shown.
12. Remove the lower inner shaft housing bushing using the J45850.
13. Remove the inner shaft housing from the vise.
14. Install the differential carrier assembly into a vise.
Clamp only on the mounting flange of the differential carrier assembly case.
15. Remove the left inner shaft using a hammer and a brass drift.
16. Remove the inner shaft seal cover bolts.
17. Remove the inner shaft seal cover.
18. Remove the left side differential bearing adjuster lock bolt.
19. Remove the left side differential bearing adjuster lock.
20. Remove the right side differential bearing adjuster lock bolt.
21. Remove the right side differential bearing adjuster lock.
22. Remove the differential carrier assembly from the vise.
23. Remove the differential carrier assembly bolts.
24. Separate the right carrier case half from the left carrier case half by tapping on the carrier case using a hammer and a brass drift.
25. Remove the differential case assembly.
26. Remove the left differential bearing adjuster by doing the following:
26.1. Install the J45224 onto the differential bearing adjuster.
26.2. Turn the J45224 counterclockwise in order to remove the differential bearing adjuster.
27. Remove the differential bearing cup.
28. Remove the right differential bearing adjuster by doing the following:
28.1. Install the J45224 onto the differential bearing adjuster.
28.2. Turn the J45224 counterclockwise in order to remove the differential bearing adjuster.
29. Remove the differential bearing cup.
30. Remove the left inner shaft bearing using the J45232 (2) and the J8092 (1).
31. Install the J8614-01 onto the pinion yoke as shown.
Remove the pinion nut while holding the J8614-01.
32. Remove the washer.
33. Install the J8614-2 (2) and the J8614-3 (3) into the J8614-01 (1) as shown.
34. Remove the pinion yoke by turning the J8614-3 (3) clockwise while holding the J8614-01 (1).
35. Install the J45234 onto the left differential carrier case and over the drive pinion as shown.
36. Remove the drive pinion by turning the forcing screw of the J45234 clockwise.
37. Remove the pinion oil seal using a suitable seal removal tool.
38. Remove the outer pinion bearing.
39. Remove the collapsible spacer from the pinion.
40. Remove the inner pinion bearing by installing the J22912-01 between the pinion bearing and the pinion gear and pressing the bearing off the pinion.
41. Remove the pinion gear selectable shim.
42. Install the J45228-4 to the outer pinion bearing cup as shown.
43. Install the J45228-1 (2) and the J45228-5 (1) to the J45228-4.
Seat the ridge of the J45228-1 (2) into the outer pinion bearing cup bore.
44. Remove the outer pinion bearing cup by turning the J45228-5 (1) clockwise.
45. Install the J45228-4 to the inner pinion bearing cup as shown.
46. Install the J45228-1 (1) and the J45228-5 (2) to the J45228-4.
47. Remove the outer pinion bearing cup by turning the J45228-5 (2) clockwise.
48. Remove the upper differential carrier assembly bushing by performing the following steps:
48.1. Install the J45850-2 (2), the J45850-3 (3). the forcing screw, the thrust bearing, the washers, and the nuts (1) over the differential carrier assembly bushing as shown.
48.2. Remove the upper differential carrier assembly bushing by holding the lower nut and tightening the upper nut of the J45850.
49. Remove the lower differential carrier assembly bushing by performing the following steps:
49.1. Install the J45850-2 (2), the J45850-3 (1), the forcing screw, the thrust bearing. and the nuts (3) over the differential carrier assembly bushing as shown.
49.2. Remove the lower differential carrier assembly bushing by holding the upper nut and tightening the lower nut of the J45850.