Pinion, Drive Gear and Differential Case Carrier

Disassembly

1. Remove the front axle from the vehicle. Refer to Axle, Front in the Removal and Installation portion of this section.

2. Remove the axle shafts. Refer to Axle Shaft in the Removal and Installation portion of this section.

3. Position suitable container under differential carrier. Remove axle housing cover (4033) and drain lubricant from axle. The lubricant will drain out as the axle housing cover is removed. Tip carrier to allow lubricant to drain completely.

4. Remove any residual gasket material from carrier mating surface. Also clean cover face of carrier, making sure it is free of any nicks or burrs.

5. NOTE: Mating letters are stamped on bearing caps and carrier. Letters are in vertical and horizontal positions. Note the letter positions before removal. At time of assembly they are to be assembled exactly as removed.

   Loosen capscrews and remove bearing caps.

   
   
   Differential Assembly
   
   
   
   
   
   

   Item	Part Number	Description
   1	—	Bearing Cap (Part of 3010)
   2	4222	Differential Bearing Cup
   3	4211	Differential Pinion Shaft
   4	4228	Differential Side Gear Thrust Washer
   5	4236	Differential Side Gear
   6	4215	Differential Pinion Gear
   7	4230	Differential Pinion Thrust Washer
   8	—	Carrier (Part of 3010)
   9	4109	Preload Shims
   10	4616	Differential Drive Pinion Bearing Cup
   11	4670	Front Axle Pinion Shaft Oil Slinger
   12	372632-S	Washer
   13	354845-38	Nut
   14	4851	Front Axle Universal Joint Flange
   15	4859	Drive Pinion Oil Seal Deflector
   16	4676	Front Axle Drive Pinon Seal
   17	4621	Differential Pinion Bearing
   18	3254	Axle Shaft Oil Seal
   19	4672	Drive Pinion Shims
   20	4628	Front Axle Pinion Bearing Cup
   21	4630	Differential Pinion Bearing
   22	3222	Ring Gear and Pinion
   23	4241	Differential Pinion Shaft Lock Pin
   24	1244	Differential Bearing
   25	4204	Differential Case
   26	4033	Axle Housing Cover
   27	350672-S	Bolt
   28	4067	Differential Bearing Shim
   29	853051-S	Fill Plug
   30	3C323	Bolt
   31	355765-S	Bolt
   A	—	Tighten to 298-379 Nm (220-280 Lb-Ft)
   B	—	Tighten to 136-172 Nm (100-120 Lb-Ft) for Grade 9. For Grade 9 (C7 Lines on Bolt Head), Tighten to 176-190 Nm (130-140 Lb-Ft)
   C	—	Tighten to 28-34 Nm (21-25 Lb-Ft)
   D	—	Tighten to 41-54 Nm (30-40 Lb-Ft)
   E	—	Tighten to 109-122 Nm (80-90 Lb-Ft)

   
   
   
   
   

6. Place Differential Housing Spreader TOOL-4000-E or equivalent on the differential case (4204). Install Dial Indicator/Magnetic Base D78P-4201-B or equivalent on the carrier housing. Do not spread housing more than 0.38mm (0.015 inch).

   
   
   
   
   

7. NOTE: Use caution to avoid damage to ring gear and drive pinion.

   Pry differential case from carrier with two pry bars. After differential case has been removed, remove spreader. Mark or tag bearing cups for correct positioning during assembly.

   
   
   
   
   

8. Remove differential bearings with Pinion and Carrier Bearing Puller D81L-4220-A or equivalent. Place tool in a vise when removing bearing. Wire differential bearing shims (4067), differential bearing cup (4222) and bearing cone together. Identify from which side they were removed. (Ring gear side or opposite side.) If differential bearing shims are damaged, replace during assembly.

9. Reposition differential case in puller and remove other bearing cone as described above. Replace bearings whenever they are removed from the carrier.

   
   
   
   
   

10. Place a few shop towels over the vise to prevent the ring gear teeth from being nicked when ring gear falls from the differential carrier.

11. NOTE: Whenever removing the ring gear bolts, always replace with new bolts upon assembly.

    Place differential case in vise. Remove bolts. Tap ring gear with a rawhide hammer to free it from the differential case. Remove differential case and ring gear from vise.

    
    
    
    
    

12. Replace differential case in vise and use a small drift to drive out the roll pin that secures the differential pinion shaft (4211).

    
    
    
    
    

13. Remove differential pinion shaft with drift.

    
    
    
    
    

14. To remove differential side gears (4236) and pinion gears, rotate the differential side gears. This will allow the differential pinion gears (4215) to turn to the opening of the case.

15. Remove differential pinion gears and the differential pinion thrust washer (4230) behind the differential pinion gears.

16. Lift out differential side gears and differential side gear thrust washers (4228).

17. NOTE: If excessive wear is visible on all parts, it is suggested that the complete differential be replaced. If any one of the gears are to be replaced, replace as a set.

    Inspect all parts, including the machined surfaces of the differential case itself.

    
    
    
    
    

18. Turn nose of carrier in a horizontal position, remove pinion nut. Hold end yoke or flange with Companion Flange Holding Tool T57T-4851-B and remove pinion nut and washer.

19. Remove end yoke or flange with Companion Flange Remover T65L-4851-B. If end yoke or flange shows wear in the area of the seal contact, replace.

20. Remove pinion by tapping with a rawhide hammer. Catch the pinion with your hand to prevent it from falling to the ground and being damaged.

    
    
    
    
    

21. Pull out pinion seal with Bearing Cup Puller T77F-1102-A and Impact Slide Hammer T50T-100-A. Discard pinion seal. Replace with new pinion seal at time of assembly.

    
    
    
    
    

22. NOTE: Service kit has 10 drive pinion shims (preload) of various thicknesses.

    NOTE: On the spline end of the pinion there are drive pinion shims (preload). These shims may stick to the pinion (part of ring gear) or bearing or even fall out. These drive pinion shims are to be collected and kept together since they will be used later in assembly. Try not to damage drive pinion shims. If drive pinion shims are damaged, replace with new ones. Drive pinion shims are available in the Pinion Preload Shims chart.

    Remove differential pinion bearing (4621), outer oil slinger and preload shims.

23.  CAUTION: Do not nick carrier bore.

    NOTE: The inner carrier section may vary in pinion bore depth due to the possibility of the need for either a baffle or oil slinger or both.

    NOTE: Shims are located between the bearing cup and carrier bore and may also include an oil slinger. If shims and oil slingers are bent or nicked, replace at time of assembly. Wire shim stacks together and measure each. If stack has to be replaced, replace with same thickness.

    NOTE: Both baffle and oil slinger are part of the drive pinion shims and are to be kept intact for assembly.

    NOTE: The baffle serves the same purpose as a dam, to ensure the differential pinion bearings are maintained with lubricant. The slinger assists lubricant flow up through the oil channels to lubricate the differential pinion bearings. If used, they are part of the pinion setting adjustment.

    Turn nose of carrier down. Remove outer differential drive pinion bearing cup (4616) with Pinion Bearing Cup Remover D81T-4628-D and Driver Handle D81L-4000-A or their equivalents. Locate driver on back edge of differential drive pinion bearing cup; drive differential drive pinion bearing cup out of carrier.

24. Remove the inner bearing cup and shims with Pinion Bearing Cup Remover D81T-4628-A and Driver Handle D81L-4000-A or equivalents.

    
    
    Bearing Cup Removal
    
    
    
    
    
    

    Item	Part Number	Description
    1	D81T-4628-A	Pinion Bearing Cup Remover — Inner
    2	D81T-4628-D	Pinion Bearing Cup Remover — Outer
    3	D81L-4000-A	Driver Handle
    4	4616	Differential Drive Pinion Bearing Cup (Outer)

25. Remove differential pinion bearings from pinion with Pinion and Carrier Bearing Puller D81L-4220-A or equivalent. Bend the slinger as required to obtain clearance for remover tool installation. Discard the slinger.

    
    
    
    
    
    
    
    
    

26. If required, remove the inner axle shaft oil seals (3254) with Jet Plug Remover T77L-9533-B. Thread the remover tool into the axle shaft oil seal, remove and discard axle shaft oil seal. Thread the remover tool into the metallic seal housing, remove and discard seal housing.

    
    
    Inner Axle Shaft Seal Removal