Removal

FRONT AXLE - 181FBI

DIFFERENTIAL

REMOVAL
1. Remove differential cover and fluid to drain.
2. Remove hub bearings and axle shafts.

Fig. 48 BEARING CAP IDENTIFICATION:

3. Note the installation reference letters stamped on the bearing caps and housing machined sealing surface (Fig. 48).
4. Loosen the differential bearing cap bolts.

Fig. 49 SPREADER LOCATION:

5. Position Spreader W-129-B and Adapter from Kit 6987, with the tool dowel pins seated in the locating holes (Fig. 49). Install holddown clamps and tighten the tool turnbuckle finger-tight.

Fig. 50 DIAL INDICATOR LOCATION:

6. Install Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to guide pin. Load indicator plunger against the opposite side of the housing (Fig. 50) and zero indicator.

Fig. 51 SPREAD DIFFERENTIAL HOUSING:

7. Spread housing while measuring the distance with the dial indicator (Fig. 51).

CAUTION: Do not spread over 0.50 mm (0.020 inch). Failure to heed caution may result in damage.

8. Remove dial indicator.
9. Hold differential case in position while removing differential bearing caps.

Fig. 52 DIFFERENTIAL CASE:

10. Remove differential from the housing (Fig. 52).
11. Remove spreader from housing.
12. Clean housing cavity with a flushing oil, light engine oil or lint free cloth.

NOTE: Do not use water, steam, kerosene or gasoline for cleaning.

DISASSEMBLY
1. Remove ring gear.

Fig. 53 MATE SHAFT ROLL PIN:

2. Drive out roll pin holding pinion gear mate shaft with a punch (Fig. 53).
3. Remove pinion gear mate shaft from the differential case and pinion mate gears.

Fig. 54 PINION MATE GEAR:

4. Rotate differential side gears and remove pinion mate gears and thrust washers (Fig. 54).
5. Remove differential side gears and thrust washers.

ASSEMBLY
1. Install differential side gears and thrust washers.
2. Install pinion mate gears and thrust washers.
3. Install pinion gear mate shaft. Align roll pin holes in shaft and the differential case.

Fig. 55 MATE SHAFT ROLL PIN:

4. Install pinion mate shaft roll pin in the differential case (Fig. 55).
5. Install the ring gear.

INSTALLATION

NOTE: If replacement differential bearings or differential case are being installed, differential side bearing shim requirements may change. Refer to Adjustments (Differential Bearing Preload and Gear Backlash) to determine the proper shim selection.

Fig. 56 SPREADER LOCATION:

1. Position Spreader W-129-B and Adapter Kit 6987, with the tool dowel pins seated in the locating holes (Fig. 56). Install holddown clamps and tighten turnbuckle finger-tight.

Fig. 57 DIAL INDICATOR LOCATION:

2. Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the lever adapter against the opposite side of the housing (Fig. 57) and zero indicator.

Fig. 58 SPREAD DIFFERENTIAL HOUSING:

3. Spread housing while measuring the distance with the dial indicator (Fig. 58).

CAUTION: Do not spread over 0.50 mm (0.020 inch). Failure to heed caution may result in damage.

4. Remove dial indicator.
5. Install differential case in the housing. Tap differential case to seat bearings cups in the housing.

Fig. 59 BEARING CAP IDENTIFICATION:

6. Install bearing caps at their original locations (Fig. 59).
7. Loosely install differential bearing cap bolts.
8. Remove axle housing spreader.
9. Tighten bearing cap bolts to 61 Nm (45 ft. lbs.).
10. Install hub bearings and axle shafts.
11. Install differential cover.