Differential Carrier Disassembly

Part 1 Of 2:

Part 2 Of 2:

REMOVE OR DISCONNECT
^ Tools Required:
- J 3289-21 Differential Holding Fixture
- J 37769 Differential Holding Fixture Adapters
- J 3289-20 Holding Fixture Bench Mount
- J 8614-01 Flange Holder
- J 22912-01 Rear Bearing Remover
- J 22888-D Side Bearing Remover
- J 8107-4 Differential Side Bearing Remover Plug
- J 26941 Axle Shaft Seal Remover
- J 23907 Slide Hammer

1. Mount differential carrier into J 3289-21 with the J 37769.





2. Place differential carrier and holding fixture into J 3289-20.
3. Scribe alignment marks on differential side bearing caps to ensure proper assembly.





4. Two bolts and side bearing lock plates from side bearing caps.





5. Four bolts and side bearing caps from differential carrier.





6. Side bearing adjusters and bearing races from differential carrier.
7. Differential ring gear and case from differential carrier.
8. Turn differential carrier and holding fixture over so that pinion flange nut is horizontal (90 degrees).
9. One bolt and rear wheel speed sensor (if equipped).
10. Unstake pinion flange nut.








11. Pinion flange nut from pinion gear using J 8614-01 to hold the pinion flange stationary.





12. Pinion gear from differential carrier.





13. Pinion seal from differential carrier using J 26941 with J 23907.





14. Outer pinion bearing from differential carrier.





15. Inner pinion bearing race from differential carrier using a large drift punch and hammer. Tap around the rear of the rear of the bearing race and slowly drive each race out evenly.





16. Outer pinion bearing race from differential carrier using a large drift punch and hammer. Tap around the rear of the rear of the bearing race and slowly drive each race out evenly.





17. Side bearings from differential case using J 22888-D with J 8107-4.





18. Ten bolts and ring gear from differential case.
19. Separate right and left differential case halves.
20. Speed sensor exciter ring from left case using a copper hammer. Tap gently around the outer edge of the exciter ring evenly until the exciter ring is free of the left differential case half.





21. Three roll pins from right differential case using a hammer and standard drift punch and disassemble side gears and washers, differential pinion gears and washers, cross shafts, and pinion cross shaft joint.
22. Collapsible spacer from pinion gear shaft.





23. Inner pinion bearing from pinion gear shaft using J 22912-01. Place the J 22912-01 on the pinion gear shaft with the concave side toward the pinion gear. Then place the pinion gear in a hydraulic press and remove the rear pinion bearing.
24. Pinion selective shim from pinion shaft.

Clean
- All parts thoroughly with solvent and air dry. If compressed air is used to dry parts, DO NOT spin dry roller bearings with compressed air or bearing damage may result.

Inspect








1. Differential carrier and case halves for cracks or stripped threads. Replace as necessary.





2. Ring and pinion gears for excessive or unusual wear, cracks, overheating or other damage. Replace as necessary.
3. All roller bearings and races for roughness, brinelling, or other wear or damage. Replace as necessary.
4. Side and differential pinion gears for unusual wear or damage. Replace as necessary.

Important: Differential components are set to very close tolerances and prone to wear should one component fail. To ensure accurate adjustment and even wear, the ring and pinion gears as well as all tapered roller bearings and races must be replaced as sets.