Disassembly and assembly. Cleaning and inspection

Disassembly and assembly

Standard differential

DISASSEMBLY

(1) Remove ring gear.

(2) Remove roll-pin holding mate shaft in housing.

(3) Remove pinion gear mate shaft (Fig. 33).

(4) Rotate the differential side gears and remove the pinion mate gears and thrust washers (Fig. 34).

(5) Remove the differential side gears and thrust washers.

ASSEMBLY

(1) Install the differential side gears and thrust washers.

(2) Install the pinion mate gears and thrust washers.

(3) Install the pinion gear mate shaft.

Fig. 33 Pinion Mate Shaft Removal

1 - PINION MATE GEAR

2 - PINION MATE SHAFT

3 - SIDE GEAR

4 - DRIFT

Fig. 34 Pinion Mate Gear Removal

1 - THRUST WASHER

2 - SIDE GEAR

3 - PINION MATE GEAR

(4) Align the hole in the pinion gear mate shaft with the hole in the differential case.

(5) Install and seat the pinion mate shaft roll-pin in the differential case and mate shaft with a punch and hammer (Fig. 35). Peen the edge of the roll-pin hole in the differential case slightly in two places, 180 apart.

(6) Lubricate all differential components with hypoid gear lubricant.

(7) Install ring gear.

Fig. 35 Pinion Mate Shaft Roll-Pin Installation

1 - PUNCH

2 - PINION MATE SHAFT

3 - MATE SHAFT LOCKPIN

Cleaning and inspection

Axle components

Wash differential components with cleaning solvent and dry with compressed air. Do not steam clean the differential components.

Wash bearings with solvent and towel dry, or dry with compressed air. DO NOT spin bearings with compressed air. Cup and bearing must be replaced as matched sets only.

Clean axle shaft tubes and oil channels in housing.

Inspect for;

• Smooth appearance with no broken/dented surfaces on the bearing rollers or the roller contact surfaces.
• Bearing cups must not be distorted or cracked.
• Machined surfaces should be smooth and without any raised edges.
• Raised metal on shoulders of cup bores should be removed with a hand stone.
• Wear and damage to pinion gear mate shaft, pinion gears, side gears and thrust washers. Replace as a matched set only
• Ring gear and pinion for worn and chipped teeth.
• Ring gear for damaged bolt threads. Replaced as a matched set only.
• Companion flange for cracks, worn splines, pitted areas, and a rough/corroded seal contact surface.

  Repair or replace as necessary.

• Preload shims for damage and distortion. Install new shims, if necessary.