SMU - Revised Differential Overhaul (11.5 inch Axle) Procedure

This bulletin is being issued to revise the Differential Overhaul (11.5 Inch Axle) procedure in the Rear Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information.

The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page.

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: Do not pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.

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 ring onto the pinion shaft.
2. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
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 into the differential case 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 pinion 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 Cautions and Notices.

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.