Differential Carrier Cover and Seal Replacement - Right Side W/O RPO KNR

Tools Required

1. Remove the right rear wheel drive shaft. Refer to Wheel Drive Shaft Replacement .
2. Remove the right rear muffler assembly. Refer to Exhaust Muffler Replacement - Right Side .
3. Drain the differential fluid. Refer to Rear Axle Lubricant Replacement .
4. Support the differential assembly.
5. Remove the right differential mount.
6. Remove the retaining bolts and push out the dowel pin.
7. Remove the differential cover.



8. Remove and discard the axle seal (1,4).



9. Install the DT-47596  (2) into the right cover. Tighten securely into the bearing cup.
10. Place the J 45124  (1) over the DT-47596  (2). adjust the legs for the best fit. Install the supplied bolt, nut thrust and washer. Hold the bolt and tighten the nut to remove the bearing cup and shim.



11. Mark or tag the shim for assembly.




Important: Whenever service requires the replacement of the right side differential cover, the covers MUST be measured and the right shim pack adjusted to compensate for machining tolerances between the two components. Failure to perform this measurement procedure may result in improper differential bearing preload.

12. Use a vernier caliper (2), a straight edge (1), and J 42168-16  (3) in order to measure the NEW differential cover bore dimension. Record the measurement as value A.
13. Use a vernier caliper (2), a straight edge (1), and J 42168-16  (3) in order to measure the old differential cover bore dimension. Record the measurement as value B.
14. Subtract value B from value A. If the computation is a positive value, add shims equal to the value, to the existing shim pack. If the computations a negative value, subtract shims equal to the value, from the existing shim pack.

1. Install the selected shims (2) and the bearing race (1) to the New cover.



2. Press the shims and bearing race into the New cover using the J 42170 and a hydraulic press.



3. Clean the O-ring sealing surface on the differential cover and the differential housing.
4. Install a NEW O-ring (4) to the differential cover (3).



5. Install the differential cover.

Notice: Refer to Fastener Notice in the Preface section.

6. Install the dowel pin and the differential cover retaining bolts.

Tighten
Tighten the retaining bolts to 28 N·m (20 lb ft).




7. Install the axle seal into the differential cover using J 46405 .
8. Fill the rear axle differential with the proper fluid and level. Refer to Rear Axle Lubricant Replacement .
9. Install the right rear muffler. Refer to Exhaust Muffler Replacement - Right Side .
10. Install the right rear wheel drive shaft. Refer to Wheel Drive Shaft Replacement .

Differential Carrier Cover and Seal Replacement - Right Side RPO KNR

Tools Required

1. Remove the right rear wheel drive shaft. Refer to Wheel Drive Shaft Replacement.
2. Remove the right rear muffler assembly. Refer to Exhaust Muffler Replacement - Right Side.
3. Drain the differential fluid. Refer to Rear Axle Lubricant Replacement.
4. Support the differential assembly.
5. Remove the right differential mount.
6. Remove the retaining bolts.
7. Remove the differential cover.
8. Remove and discard the axle seal (1, 4).



9. Install the DT-47596  (2) into the right cover. Tighten securely into the bearing cup.
10. Place the J 45124  (1) over the DT-47596  (2). Adjust the legs for the best fit. Install the supplied bolt, nut thrust and washer. Hold the bolt and tighten the nut to remove the bearing cup and shim.



11. Mark or tag the shims (1, 2) for assembly.




Important: Whenever service requires the replacement of the right side differential cover, the covers MUST be measured and the right shim pack adjusted to compensate for machining tolerances between the two components. Failure to perform this measurement procedure may result in improper differential bearing preload.

12. Use a vernier caliper (2) and a straight edge (1), in order to measure the NEW differential cover bore dimension. Record the measurement as value A.
13. Use a vernier caliper (2) and a straight edge (1), in order to measure the old differential cover bore dimension. Record the measurement as value B.
14. Subtract value B from value A. If the computation is a positive value, add shims equal to the value, to the existing shim pack. If the computations a negative value, subtract shims equal to the value, from the existing shim pack.

1. Install the selected shims (2) and the bearing race (1) to the new cover.



2. Press the shims and bearing race into the new cover using the J 42170 and a hydraulic press.



3. Clean the O-ring sealing surface on the differential cover and the differential housing.
4. Install a NEW O-ring (4) to the differential cover (3).
5. Install the differential cover.

Notice: Refer to Fastener Notice in the Preface section.

6. Install the differential cover retaining bolts.

Tighten
Tighten the retaining bolts to 28 N·m (20 lb ft).




7. Install the axle seal into the differential cover using J 46405 .
8. Fill the rear axle differential with the proper fluid and level. Refer to Rear Axle Lubricant Replacement.
9. Install the right rear muffler. Refer to Exhaust Muffler Replacement - Right Side.
10. Install the right rear wheel drive shaft. Refer to Wheel Drive Shaft Replacement.