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 pinion stem. If installing new differential ring gear and pinion it is not necessary to mark rear axle universal joint flange.
NOTE: Replacing flange yoke seals involves removal and installation of only pinion nut and rear axle universal joint flange.
2. Hold rear axle universal joint flange with Companion Flange Holding Tool T78P-4851-A and loosen pinion nut.
3. With pinion nut still engaged by a few threads install 2-Jaw Puller D80L-1002-L or equivalent and pull rear axle universal joint flange loose on splines.
4. Remove puller, nut and rear axle universal joint flange.
5. With a soft-faced hammer, drive the drive pinion out of the differential pinion bearing and remove through rear of rear axle housing.
6. Remove rear axle drive pinion seal. Pinion Seal
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