Special Tools

1. Remove the differential carrier assembly from the vehicle. Refer to Front Differential Assembly Replacement.



2. Remove the bolts retaining the front axle shaft housing tube to the front drive axle housing.
3. Remove the front axle shaft housing tube assembly.



4. Install the J 45935 fixture (1) to the front drive axle housing using axle mounting bolts.
5. Insert the J 45935 fixture (1) into the bench mounting fixture J 34178 adapter (2).
6. Install the locking pin J 3289-22 (3), then tighten the set screw (4).



7. Remove the front axle housing cover bolts.
8. Remove the front axle housing cover and gasket.



9. Install the J 45222-10 adapters (1) to the front axle housing.
10. Install the J 45222 spreaders (2) to the J 45222-10 adapters .



11. Install the J 8001-1 clamp (2), the J 8001-2 sleeve (3), the J 34178 adapter (4, 6), and the J 8001-3 indicator (5).
12. Preload the J 8001-3 indicator approximately 3/4 of a turn clockwise.
13. Rotate the indicator housing to align the indicator needle of the J 8001-3 indicator (5) and the dial indicator face to ZERO.
14. Spread the axle housing by turning the clevis screw of the J 34178 adapter while observing the J 8001-3 indicator . Spread the housing just enough to remove the differential assembly. DO NOT spread the housing more than 1.02 mm (0.040 in).



15. Mark the bearing caps left and right then remove the bearing cap bolts and the bearing caps.

Note: Steps 16 and 18 are for those vehicles equipped with the electronic locking differential.

16. Remove the electronic locking differential coil bracket
17. Remove the electronic locking differential grommet by passing it into the differential case.
18. Relocate the electronic locking differential wire and grommet to the side so that it is not damaged during the differential case removal.




Warning: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.

Caution: When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.

19. Using a pry bar and a block of wood, remove the differential case from the axle housing.

Note: Mark the cups and shims left and right and in order as necessary. Place the cups and the shims with the bearing caps.

20. Remove the bearing cups, the shims, and the spacers as necessary.
21. Remove the J 8001-1 clamp , the J 8001-2 sleeve , the J 34178 adapter and the J 8001-3 indicator .
22. Remove the J 45222 spreader and the J 45222-10 adapters .

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



2. Install the J 45222-10 adapters (1) and the J 45222 spreader (2) to the front axle housing.



3. Install the J 8001-1 clamp (2), the J 8001-2 sleeve (3) the J 34178 adapter (4, 6), and the J 8001-3 indicator (5).
4. Preload the J 8001-3 indicator (5) approximately 3/4 of a turn clockwise.
5. Rotate the indicator housing to align the indicator needle of the J 8001-3 indicator (5) and the dial indicator face to ZERO.
6. Spread the axle housing by turning the clevis screw of the J 34178 adapter while observing the J 8001-3 indicator . Spread the housing just enough to remove the differential assembly. DO NOT spread the housing more than 1.02 mm (0.040 in).

Note: Step 7 is for those vehicles equipped with the electronic locking differential.

7. Install the electronic locking differential coil wire and grommet in the differential housing.



8. Place the case with the bearing cups installed into the axle housing.

Note: Step 9 is for those vehicles equipped with the electronic locking differential.

9. Install the electronic locking differential coil wire bracket on the side bearing caps.

Note: Do not torque the bearing cap bolts at this time. Hand tighten the bearing cap bolts.

10. Install the bearing caps and bolts.
11. Adjust the differential side bearing preload. Refer to Drive Pinion and Ring Gear Replacement.
12. Adjust the backlash. Refer to Backlash Inspection and Adjustment.
13. Perform the gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection.

Caution: Refer to Fastener Caution in the Preface section.

14. Tighten the bearing cap bolts to 63 N·m (46 lb ft).
15. Install the front axle housing cover gasket.
16. Install the front axle housing cover and bolts 30 N·m (22 lb ft).
17. Install the front axle shaft housing tube assembly to the front drive axle housing.
18. Install the bolts retaining the front axle shaft housing tube assembly to the front drive axle housing 60 N·m (44 lb ft).
19. Remove the J 45935 fixture from the front drive axle housing.
20. Install the differential carrier assembly to the vehicle. Refer to Front Differential Assembly Replacement.