Usage:
Start By:
a. remove differential (front)
1. Mount the front differential on tooling (A).
2. Remove roll pin (1) and adjusting nut (2) from each side of the axle carrier.
3. Remove bearing cups (3) from each side of the axle carrier.
Typical Example
| NOTICE |
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If the outer cage of bearing (4) was cut, bearing (4) must be discarded and replaced with a new part. |
4. Use tooling (B) and remove bearing (4) from the bevel gear end of the differential carrier. If tooling (B) is not available, use a cold chisel and cut the outer cage of bearing (4). Remove the outer cage and the rollers from bearing (4).
5. Put an alignment mark on differential gear case halves (7) and (8) for assembly purposes. The components must be reinstalled in their original positions.
6. Tilt the differential carrier to allow access to hex socket head bolts (5). Remove the twelve bolts (5) and four locks (6).
7. Note the configuration of locks (6) on bolts (5) and the differential carrier. Mark, if necessary.
8. Reposition the front differential as shown.
9. Support differential gear (10) (differential gear located inside upper differential gear case half) in differential gear case half (8) and remove the differential gear and differential gear case half as a unit from the axle carrier.
10. Remove differential gear (10) from the differential gear case half (8).
11. Remove thrust washer (13), five plates (11) and four discs (12) located under differential gear (10).
NOTE: Note the two differential surfaces on thrust washer (13). For assembly purposes, the rough side should face the plates and discs and the smooth side should face differential gear (10).
12. If the outer cage of bearing (4) was cut, use tooling (C) and remove the inner race of bearing (4) from differential gear case half (8).
13. Use tooling (D) and a press, and remove bevel gear (9) from the differential gear case half (8).
14. If necessary, remove four inner roll pins (15) and four outer roll pins (14).
15. Inner roll pins (15) fit inside outer roll pins (14) and expand as each is pressed into differential half (8). Roll pins may have to be destroyed if they must be removed. Inspect pins closely for wear or damage and replace if necessary.
16. Remove spider assembly (16) from differential gear case half (7).
17. Remove differential gear case half (7) from the axle carrier.
18. Remove four thrust washer (17) and four bevel gears (18) from spider (16).
19. Disassemble spider assembly (16).
20. Remove differential gear (19) from differential gear case half (7).
21. Remove thrust washer (22), five plates (21) and four discs (20) located under differential gear (19).
NOTE: Note the two different surfaces on thrust washer (22). For assembly purposes, the rough side should face the plates and discs and the smooth side should face the differential gear (19).
22. Use tooling (E) and remove bearing and bearing cone (23) from differential gear case half (7).
23. Remove four bolts (28) and two straps (24) from drive flange (25).
24. Use a punch and bend lock plate (27) free from two pockets (X) located in drive flange (25). Remove nut (28), lock plate (27) and the washer. Remove drive flange (25) from the pinion assembly.
NOTE: Support pinion (29) from underneath to prevent the pinion from falling to the floor as it is pressed from the axle carrier.
25. Remove the axle carrier from tooling (A). Put the axle carrier in a press and remove pinion assembly (29) from the axle carrier.
26. Remove spacer (30) from pinion (29).
27. Use tooling (F) and a press, and remove bearing cone (31) from pinion (29).
28. Mount the axle carrier on tooling (A).
29. Remove seal (32), bearing cone (33) and bearing cup (34) from the axle carrier.
30. Remove bearing cup (35) from the axle carrier.
Assemble Differential (Front) (Limited Slip)
| NOTICE |
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The bevel gear and the pinion are a matched set, if either part is worn, replacement of both parts must be made. |
NOTE: The pinion depth procedure is only necessary if the axle carrier or the bevel gear and pinion set is replaced.
1. Adjust the pinion depth as follows:
a. Install tooling (G). Measure the top of the measuring shaft, which is part of tooling (G), to the bottom face of the bearing cup counterbore. This measurement will be Dimension (A), [153.23 mm (6.033 in)].
b. Measure the diameter of bar (36). This measurement will be Dimension (B), [30.0 mm (1.181 in)]. Divide Dimension (B) by two to determine Dimension (C), [15.0 mm (.591 in)]. Subtract Dimension (C) from Dimension (A). This dimension will be Dimension (X), [138.23 mm (5.442)]. Dimension (X) is the distance from the centerline of the axle carrier bores to the bottom face of the pinion bearing cup counterbore.
c. Measure the thickness of bearing cone (31) and bearing cup (35) as an assembled unit, [25.48 mm (1.003 in)]. Subtract this dimension from Dimension (X). This dimension will be Dimension (D), [112.75 mm (4.439 in)]. Dimension (D) is the distance from the centerline of the axle carrier bores to the bearing locating shoulder of the pinion.
NOTE: Stamped on the end of the pinion is the nominal dimension, [112.0 mm (4.409 in)]. Etched on the end of the pinion is the deviation from the nominal dimension, [-0.1 mm (-.004 in)]. Also etched on the end of the pinion is an identification number for the pinion and bevel gear set.
d. Add the deviation to the nominal dimension. This will be the actual pinion dimension, [111.9 mm (4.405 in)]. Example: 112.0 mm + (-0.1 mm) = 119.9 mm [4.409 in + (-.004 in) = 4.405 in].
e. From Dimension (D) subtract the actual pinion dimension. This dimension will be the shim thickness required, [0.85 mm (.034 in)].
NOTE: If necessary, use tooling (J) to seat bearing cups (34) and (35).
2. Lower the temperature of bearing cup (35) and install the required shim and the bearing cup in the axle carrier.
3. Lower the temperature of bearing cup (34) and install the bearing cup in the axle carrier.
4. Heat bearing cone (31) to a maximum temperature of 135°C (275°F). Install the bearing cone on pinion (29). Be sure inner race of the bearing cone is seated against the locating shoulder on the pinion.
5. Install pinion assembly (29) in the axle carrier.
| NOTICE |
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Prior to the installation of tooling (K) on pinion assembly (29), measure from the top of the three measuring pins to the back face. This measurement must be greater than the largest available spacer. If necessary adjust the measuring pins. |
| NOTICE |
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Tooling (K) must be installed on the pinion assembly with three measuring pins facing toward the threaded end of the pinion assembly. |
6. Install the measuring ring, tooling (K), in place of the spacer on the pinion assembly.
7. Heat bearing cone (33) to a maximum temperature of 135°C (275°F). Install the bearing cone on pinion (29).
8. Install drive flange (25), washer (36) and nut (26) on pinion assembly (29).
| NOTICE |
|---|
The three measuring pins, located in tooling (K), will be pushed into the measuring ring as nut (26) is tightened. While tightening the nut, do not exceed a rolling torque of 2 N·m (18 lb in). If the rolling torque does exceed 2 N·m (18 lb in), the three measuring pins located in tooling (K) will be pushed into the measuring ring to far, causing an incorrect spacer measurement. The pinion assembly must then be disassembled and the three measuring pins readjusted and Steps 5 through 9 must be repeated. |
9. Tighten nut (26) until a rolling torque of 1 to 2 N·m (9 to 18 lb in) [2 N·m (18 lb in) preferred] is obtained.
10. Remove nut (26), washer (36) and drive flange (25) from pinion (29).
11. Remove the axle carrier from tooling (A) and put the axle carrier in a press. Remove pinion assembly (29) and tooling (K) from the axle carrier.
12. Remove tooling (K) from pinion assembly (29).
13. On tooling (K), measure the distance from the top a measuring pin to the back face. This dimension will be the spacer thickness required (See Chart).
14. Install required spacer (30) on pinion assembly (29).
15. Install pinion assembly (29) in the axle carrier.
16. Heat bearing cone (33) to a maximum temperature of 135°C (275°F). Install the bearing cone on pinion (29).
17. Put 7M7456 Bearing Mount on the outside diameter of seal (32). Use tooling (L) and install the seal in the axle carrier with the seal lip facing toward the pinion. Lubricate the rubber lip of seal (32) with a light film of 5P3975 Rubber Lubricant.
18. Install drive flange (25), washer (36) and nut (26) on the pinion assembly (23). Use tooling (L) and tighten nut to a torque of 300 to 350 N·m (220 to 260 lb ft).
NOTE: The installation of seal (32) in the axle carrier will add approximately 1 N·m (9 lb in) of rolling resistance to the pinion.
19. Check the rolling torque. The rolling torque of the pinion with seal (32) installed must be 2 to 3 N·m (18 to 37 lb in).
20. Install lock plate (27). Drive lock plate (27) over nut (26) with the socket used to tighten the nut. Round of the end of a piece of 5/16 " drill rod and stake the lock plate in pockets (X).
21. Put two straps (24) in position on drive flange (25) and install four bolts (28).
22. Heat bearing cone (23) to a maximum temperature of 135°C (275°F). Install the bearing cone on differential gear case half (7). Be sure inner race of the bearing cone is seated against the locating face on the differential gear case half.
23. Measure the thickness of thrust washer (22) and thrust washer (13) and write it down. This measurement will be needed later.
24. Assemble five plates (20) and four disc plates (21) and one thrust washer (22). The first plate (20) should be on the bottom furthest from differential gear (19). Alternate the plates and the discs.
25. Install thrust washer (22) on the spline of differential gear (19). Insure that the machined (smooth) side of thrust washer (22) is against the back of the gear. Place plates (20) and discs (21) in alternate manner on the splines of differential gear (19). This will align the discs.
26. Align the side tabs on each of the five plates (20) and install into the differential housing as a unit.
27. Assemble spider shafts (16) as shown and install four bevel gears (18) and four thrust washers (17) on spider (16) as shown. Insure that the tabs of washers (17) are facing downward so that they can lock into differential case half (7).
28. Install spider assembly (16) in differential gear case half (8). Tabs of thrust washers (17) should be facing upward as shown. Check the backlash with tooling (M). The backlash should be 0.20 to 0.30 mm (.008 to .012 in).
29. Pick up spider assembly (16) as a unit and install it in differential gear case half (7). Be sure the tabs of thrust washers (17) are positioned in openings in the differential gear case half (7) as shown.
30. Check the backlash with tooling (M). The backlash should be 0.20 to 0.30 mm (.008 to .012 in).
31. Install thrust washer (13) on the spline of differential gear (10). Insure that the machined (smooth) side of thrust washer (13) is against the back of the gear. Place plates (11) and discs (12) in alternate manner on the splines of differential gear (19). This will align the discs.
32. Place differential gear (10) with thrust washer, discs and plates as a unit on top of spider assembly (16) as shown. Align the tabs of each of the plates.
33. Install differential gear case half (8) down over differential gear (10), discs (12) and plates (11). Note alignment marks placed on the case halves and the spider.
34. Using a depth gauge or other suitable measuring device, press on plate pack from the ring gear side and measure the plate play. The amount of plate play should be between 0.1 to 0.2 mm.
35. If the plate play is greater than the allowable dimension, note the thickness dimension of the thrust washer taken earlier in step 23. Replace the thrust washer on just that side with a new thrust washer with a thickness dimension equal to the old thrust washer plus the necessary depth measurement taken in step 34. Perform step 34 again until proper dimension is obtained for that side.
36. Turn the entire differential housing over. Using a feeler gauge as shown, measure the plate play. The amount of plate play should be between 0.1 to 0.2 mm.
37. If the plate play is greater than the allowable dimension, note the thickness dimension of the thrust washer taken earlier in step 23. Replace the thrust washer on just that side with a new thrust washer with a thickness dimension equal to the old thrust washer plus the necessary depth measurement taken in step 36. Perform step 36 again until proper dimension is obtained for that side.
38. Upon completion of the allowable dimension measurement, separate the differential hales. Remove plates, discs, thrust washers from differential case half (8).
39. If removed, install four outer (14) and four inner roll pins (15) in differential gear case half (8).
40. If replacement of bevel gear (9) was necessary, put bevel gear (9) and differential gear case half (8) in a press as shown. Be sure the roll pins located in the differential gear case half are in alignment with the corresponding holes in the bevel gear. Install two bolts (5) through the differential gear case half into the bevel gear. The two bolts will aid in the alignment of the differential gear case half to the bevel gear. Press bevel gear (9) on differential gear case (8).
41. Heat bearing cone (23) to a maximum temperature of 135°C (275°F). Install the bearing cone on differential gear case half (7). Be sure inner race of the bearing cone is seated against the locating face on the differential gear case half.
42. Reinstall clutch pack, thrust washer and differential gear if they were removed when installing bearing.
43. Install spider assembly (16) in differential gear case half (7). Be sure the tabs of thrust washers (17) are positioned in openings in differential gear case half (7) as shown.
44. Put differential gear case half (7) and spider assembly (16) as a unit in position as shown.
45. Put differential gear half (7) and spider assembly (16) as a unit in position in the axle carrier.
46. Secure clutch pack, (11) and (12) and thrust washer (13), in differential gear case half (8).
47. Install and secure differential gear (10) on top of thrust washer and in differential gear case half (8).
48. Support differential gear (10) in differential gear case half (8) and install the differential gear and differential gear case half as a unit in the axle carrier. Be sure the location marks put on the differential gear case halves during the disassembly are in alignment.
49. Support the differential carrier assembly and rotate the axle carrier to the position as shown.
50. Tilt the differential carrier assembly and install four locks (6), twelve hex socket head bolts (5). Tighten the twelve bolts to a torque of 150 N·m (110 lb ft).
51. Heat bearing cone (4) to a maximum temperature of 135°C (275°F). Install the bearing cone on differential gear case half (6). Be sure inner race of the bearing cone is seated against the locating face on the differential gear case half.
52. Install a bearing cup (3) on each side of the axle carrier.
53. Install an adjusting nut (2) on each side of the axle carrier.
54. Rotate the axle carrier to the position shown.
NOTE: Rotate the differential several times during this procedure.
55. Install tooling (M) on the bevel gear as shown. Tighten adjusting nut (2) nearest the bevel gear until the backlash of 0.20 to 0.28 mm (.008 to .011 in) is obtained.
56. Install tooling (M) on the back side of the bevel gear as shown. Tighten adjusting nut (2) opposite the bevel gear until there is zero bearing end play, then tighten this same adjusting nut an additional two notches. By tightening the adjusting nut the additional two notches after the bearings are set at zero end play will provide a bearing preload on the differential bearings of 2 to 3 N·m (18 to 27 lb in).
57. Use tooling (M) and check the backlash again. Adjust the adjusting nuts the same amount in opposite directions until the backlash is 0.20 to 0.28 mm (.008 to .011 in).
58. Install tooling (M) on the back side of the bevel gear. Rotate the bevel gear at least one turn and check the face runout. The maximum allowable runout is 0.080 mm (.0031 in).
59. Install roll pins (1) on each side of the axle carrier.
End By:
a. install differential (front)