Differential Overhaul 9.5 Inch Axle

Tools Required

Disassembly Procedure

1. Remove the differential side bearings by performing the following steps:

1.1.	Install the differential assembly into a vise.

1.2.	Install the J 36597  (1) and the J 22888-20A  (2) as shown.

1.3.	Remove the differential side bearings using the J 22888-20A .





Important: The ring gear bolts have left-hand threads.

2. Remove the gear bolts. Discard the bolts.

Notice: Refer to Ring Gear Removal Notice in the Preface section.




3. Remove the ring gear from the differential case.

Drive the ring gear off with a brass drift if necessary.




4. Remove the differential pinion gears and the differential side gears by performing the following steps:

4.1.	Remove the pinion shaft lock bolt.

4.2.	Remove the pinion shaft.

4.3.	Drive the pinion gear thrust washer out from the differential case using a hammer and a brass drift.

4.4.	Roll the differential pinion gears out of the differential case.

4.5.	Remove the differential side gears and the side gear thrust washers.

Mark the pinion gears top and bottom and the differential side gears left and right.

Assembly Procedure

1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
2. Install the differential side gear thrust washers to the differential side gears.
3. Install the differential side gears and thrust washers into the differential case.

If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to their original locations.




4. Install the differential pinion gears by performing the following steps:

4.1.	Position one of the pinion gears between the differential side gears.

4.2.	Install the second pinion gear directly opposite of the first gear between the differential side gears.

4.3.	Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case.

4.4.	Install the pinion gear thrust washers using a hammer and a brass drift.

5. Install the pinion shaft.

Notice: Refer to Fastener Notice in the Preface section.

6. Install a new pinion shaft lock bolt.

Tighten
Tighten the new pinion shaft lock bolt to 50 N·m (37 lb ft).

Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.




7. Install the ring gear to the differential case.




Important: The ring gear bolts have left-hand threads.

8. Install the new ring gear bolts.

Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

9. Tighten the ring gear bolts. Tighten the bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

Tighten
Tighten the ring gear bolts in sequence to 140 N·m (103 lb ft).




10. Install the differential side bearings by performing the following steps:

10.1.

In order to protect the differential case, install the J 36597 in the case on the side opposite the bearing installation.

10.2.

Install the J 29710  (2) and the J 8092  (1) onto the differential case bearing as shown.

10.3.

Drive the bearing onto the case using the J 29710 and the J 8092 .

Differential Overhaul 10.5 Inch Axle

Tools Required

Disassembly Procedure

1. Remove the differential side bearings by performing the following steps:

1.1.	Place a block of wood on each side of the differential case before installing the differential case into the vise.

Install the differential assembly into a vise.

1.2.	Install the J 8107-3 and the J 22888-20A onto the differential side bearing.

1.3.	Remove the differential side bearings using the J 22888-20A .




2. Remove the ring gear bolts.

Notice: Refer to Ring Gear Removal Notice in the Preface section.

3. Remove the ring gear from the differential case.

Drive the ring gear off with a brass drift if necessary.

4. Separate the differential case assembly.




Important: If the differential pinion gears, the differential side and the thrust washers are to be reused, mark the components so they can be re-installed in their original location in the differential case.

5. Remove the following from the differential case:

•	The thrust washers

•	The differential pinion gears

•	The differential pinion spider




6. Remove the differential side gears.

Assembly Procedure

1. Lubricate the differential side gears and the differential pinion gears with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations .



2. Install the differential side gears into the differential case.

If the original differential side gears are being used, install the gears in the original location.




3. Assemble the differential pinion gears and the thrust washers to the differential spider as shown.

If the original differential pinion gears, the thrust washers and the differential spider are being used, install the components in the original locations.




4. Assemble the differential case halves.

Align the arrow in the differential case as shown.

Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

5. Install the ring gear to the differential case.

Notice: Refer to Fastener Notice in the Preface section.




6. Install the new ring gear bolts.

Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

7. Tighten the ring gear bolts. Tighten the bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

Tighten
Tighten the ring gear bolts in sequence to 165 N·m (122 lb ft).

8. Install the differential side bearings by performing the following steps:

8.1.	In order to protect the differential case, install the J 8107-3 in the case on the side opposite the bearing installation.

8.2.	Install the J 29710 and the J 8092 onto the differential case bearing.

8.3.	Drive the bearing onto the case using the J 29710 and the J 8092 .

Differential Overhaul 8.6 Inch Axle

Disassembly Procedure

1. Remove the differential side bearings. Refer to Differential Side Bearings Replacement .




Important: The ring gear bolts have left-hand threads.

2. Remove the gear bolts. Discard the bolts.

Notice: Refer to Ring Gear Removal Notice in the Preface section.




3. Remove the ring gear from the differential case.

Drive the ring gear off with a brass drift if necessary.




4. Remove the differential pinion gears and the differential side gears by performing the following steps:

4.1.	Remove the pinion shaft lock bolt.

4.2.	Remove the pinion shaft.

4.3.	Roll the differential pinion gears out of the case with the pinion gear thrust washers.

4.4.	Remove the differential side gears and the side gear thrust washers.

Mark the pinion gears top and bottom and the differential side gears left and right.

Assembly Procedure

1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations .
2. Install the differential side gear thrust washers to the differential side gears.
3. Install the differential side gears and thrust washers into the differential case.

If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to their original locations.




4. Install the differential pinion gears and pinion gear thrust washers by performing the following steps:

4.1.	Position one pinion gear between the differential side gears.

4.2.	Position the second pinion gear between the differential side gears directly opposite the of the first gear.

4.3.	Rotate the differential side gears until the pinion gears is directly opposite the opening in the differential case.

4.4.	Install the thrust washers.

Rotate the pinion gears toward the differential opening in order to permit the sliding in of the thrust washers.

5. Install the pinion shaft.

Notice: Refer to Fastener Notice in the Preface section.

6. Install a new pinion shaft lock bolt.

Tighten
Tighten the new pinion shaft lock bolt to 36 N·m (27 lb ft).

Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.




7. Install the ring gear to the differential case.




Important: The ring gear bolts have left - hand threads.

8. Install the new ring gear bolts.

Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

9. Tighten the ring gear bolts. Tighten the bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

Tighten
Tighten the ring gear bolts in sequence to 120 N·m (89 lb ft).

10. Install the differential side bearings. Refer to Differential Side Bearings Replacement .

Differential Overhaul 11.5 Inch Axle

Tools Required

Disassembly Procedure

1. Remove the differential side bearings by performing the following steps:

1.1.	Install the differential assembly into a vise.

1.2.	Install the J 8107-5 (1) and the J 22888-20A  (2) as shown.

1.3.	Remove the differential side bearings using the J 22888-20A .





Important: The ring gear bolts have right-hand threads.

2. Remove the gear bolts. Discard the bolts.

Notice: Refer to Ring Gear Removal Notice in the Preface section.




3. Remove the ring gear from the differential case.

Drive the ring gear off with a brass drift if necessary.




4. Locate the end of the pinion shaft with the pilot hole.



5. Remove the pinion shaft by performing the following steps:

5.1.	Place a brass drift onto the end of the pinion shaft with the pilot hole.

5.2.	Drive the pinion shaft through the differential case using a hammer and the brass drift.




6. Remove the retaining ring from the pinion shaft. Discard the retaining ring.



7. Remove the differential pinion gears and the pinion gear thrust washers by rolling the gears out through the differential case opening.
8. Remove the differential side gears and the thrust washers.

Mark the pinion gears top and bottom and the differential side gears left and right.

Assembly Procedure

1. Install the new retaining onto the pinion shaft.
2. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations .
3. Install the differential side gear thrust washers to the differential side gears.
4. Install the differential side gears and thrust washers into the differential case.

If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to their original locations.




5. Install the differential pinion gears and the thrust washers by performing the following steps:

5.1.	Install the thrust washers to the pinion gears.

5.2.	Position one of the pinion gears with the thrust washer between the differential side gears.

If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to their original locations.

5.3.	Install the second pinion gear with the thrust washer between the differential side gears directly opposite of the first gear.

5.4.	Rotate the differential side gears until the pinion gears and the thrust washers are directly opposite the opening in the differential case.




6. Install the pinion shaft into the differential case by performing the following steps:

6.1.	Insert the side of the pinion shaft with the pilot hole into the differential case.

6.2.	Slide the pinion shaft through the differential case until the retaining ring is against the differential case.

6.3.	Carefully drive the pinion shaft into the differential case using a hammer and a brass drift.

Ensure that the pinion shaft retaining ring is seated in the channel within the differential case.





Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

7. Install the ring gear to the differential case.

Notice: Refer to Fastener Notice in the Preface section.





Important: The ring gear bolts have right - hand threads.

8. Install the new ring gear bolts.

Hand start each bolt in ensure the ring gear is properly installed to the differential case.

9. Tighten the ring gear bolts. Tighten the bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

Tighten
Tighten the ring gear bolts in sequence to 237 N·m (175 lb ft).




10. Install the differential side bearings by performing the following steps:

10.1.

In order to protect the differential case, install the J 8107-5 in the case on the side opposite the bearing installation.

10.2.

Install the J 44420  (2) and the J 8092  (1) onto the differential case bearing as shown.

10.3.

Drive the bearing onto the case using the J 44420 and the J 8092 .