For 1990-2009 cars only
Differential Case
- Clean the differential case in solvent.
- Inspect the differential case for the following conditions:
- Inspect the gears for the following conditions:
- Clean the pinion flange in solvent.
- Inspect the pinion flange for the following conditions:
Caution: Refer to Safety Glasses Caution in the Preface section.
| • | Chips or cracks |
| • | Damage to the bolts holes (1) |
| • | Unusual wear, grooves or scoring |
| • | Damaged side bearing flanges (2) |
| • | Heat discoloration |
| • | Worn differential pin bores (3) |
| • | Pitting or heat discoloration |
| • | Unusual wear or scoring in the differential pin bores (2) |
| • | Unusual wear, loss of coating, grooves or scoring on the differential pin (3) |
| • | Scored or worn side gear washers (5) and pinion gear washers (1) |
| • | Unusual wear or grooves on the axle side gear splines (4) |
| • | Splines for wear, pitting or twisting (1) |
| • | Sealing surface for grooves or pitting (2) |
Bearings and Races
- Inspect the bearing rollers and races for the following conditions:
- Inspect the bearing rollers and races for heat discoloration.
- Inspect for damaged bearing cages.
- Clean the differential carrier in solvent.
- Clean and inspect for the following:
- Clean the oil passage between (1) and (2) in the axle bearing cup bore.
- Inspect surfaces (1) and (2).
- Ensure surfaces are clean and free of nicks or burrs.
- Clean the differential cover in solvent.
- Clean and inspect the following:
- Inspect the cover axle seal mounting surface (1).
- Clean the pinion bearing housing in solvent. Air dry by blowing out the oil holes behind the cups.
- Ensure that there are no nicks or burrs on the mating surface (1) that would cause binding.
- Clean the O-ring groove (2).
| • | Pitting |
| • | Scoring or grooves |
| • | Excessive wear or other damage |
Heat discoloration ranges from a faint yellow to a dark blue color. This discoloration may result from an overload or improper lubrication. Excessive heat causes softening of the rollers and races. Bearings or races with signs of heat discoloration must be replaced.
| • | Pinion housing bolt hole threads (1) |
| • | Carrier cover bolt hole threads (2) |
| • | Carrier cover sealing area (3) |
| • | Drain plug threads (4) |
| • | Axle seal area (5) |
| • | The oil passage between (1) and (2) in the axle cup bore |
| • | The fill plug threads (3) |
| • | The O-ring groove (4) |
| • | The cup and shim surfaces (5) |
Caution: Refer to Safety Glasses Caution in the Preface section.
Important: Only use this housing if old bearings are being used. New bearings, housing and spacer are a kit. The spacer is pre-cut and cannot be done in the field.
