Disassembly
DIFFERENTIAL CASE REMOVAL1. Remove differential/axle housing.
2. Remove differential cover.
3. Position rear axle housing in Bench Mounted Holding Fixture T57L-500-B.
NOTE: The arrows face outboard on bearing caps. When assembled, the arrows must be pointing in the same direction and bearing caps must be in original positions as before removal.
4. Mark one differential bearing cap to make sure the caps are installed in their original positions during assembly.
5. Loosen differential bearing cap bolts and bearing caps.
NOTE: Arrows face outboard on bearing caps When assembled, the arrows must be pointing in the same direction as before removal with bearing caps in original positions.
6. Pry out differential case, differential bearing cups and differential bearing shims until loose in the bearing caps. Remove bearing caps and remove differential case from rear axle housing.
7. Remove differential pinion shaft lock pin and differential pinion shaft.
NOTE: If equipped with Traction-Lok(r) limited slip differential, refer to Differential Clutch for Disassembly procedure. Differential Clutch
8. Remove differential side gears, differential pinion gears and differential pinion thrust washers.
9. Inspect the differential bearings and differential bearing cups for damage. If damaged remove the differential bearings using Differential Side Bearing Puller T77F-4220-B1 and Step Plate T81P-4220-A.
10. Using a drift that will bottom in ring gear bolt holes, strike at alternate holes around gear. Remove ring gear.
11. Install differential bearings using Differential Side Bearing Replacer T57L-4221-A2.
UNIVERSAL JOINT FLANGE/DRIVE PINION REMOVAL
CAUTION: This operation disturbs the pinion bearing preload. This preload must be carefully reset when assembling.
1. Mark rear axle universal joint flange in relation to the pinion stem. Hold the rear axle universal joint flange with Companion Flange Holding Tool T78P-4851-A and remove the pinion nut.
NOTE: If installing a new rear axle universal joint flange or differential ring gear and pinion, it is not necessary to mark the rear axle universal joint flange.
2. Remove rear axle universal joint flange with Companion Flange Holding Tool T78P-4851-A.
3. With a soft-faced hammer, drive the differential ring gear and pinion out of the rear differential pinion bearing. Remove through the rear of the rear axle housing.
4. Remove the rear axle drive pinion seal.
5. Remove the front differential pinion bearing from the rear axle housing.
PINION BEARING & CUP REMOVAL
1. Using a press and Pinion Bearing Cone Remover T71P-4621-B. remove differential pinion bearing assembly from the rear axle differential pinion.
2. Remove the drive pinion bearing adjustment shim from the drive pinion.
NOTE: Measure the drive pinion bearing adjustment shim, which is found under the differential pinion bearing, with a micrometer and record the thickness. Use this as a reference to compare the shim gauge reading before installing the bearing.
3. If replacing the differential pinion bearings, tap alternately (with a brass drift of suitable length) on each side of the differential bearing cup during removal to prevent differential bearing cups from cocking in the carrier bore. Remove differential bearing cups.
NOTE: To make sure bearings are properly seated, clean bores before installing differential pinion bearings.
4. Complete disassembly by performing Differential Case Runout Check.
Testing and Inspection