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Author Topic: Differential Carrier Assembly - R&R 8.25 Inch Axle  (Read 12114 times)
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ItsStopher
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« on: 06/26/08 08:41 PM »

Differential Carrier Assembly - Disassemble 8.25 Inch Axle (02 ref)

Tools Required
  • J 22912-01 Split-Plate Bearing Puller
  • J 2619-01 Slide Hammer
  • J 29369-1 Bushing and Bearing Remover
  • J 33791 Carrier Bushing Remover/Installer
  • J 34011 Pilot Bearing Remover
  • J 36598 Holding Fixture
  • J 36599-A Side Bearing Nut Wrench
  • J 36616 Axle Mount Bushing Remover/Installer
  • J 45765 Pinion Remover
  • J 45858 Front Axle Bearing Race Remover/Installer - 8.25 Inch Axle
  • J 8614-01 Flange and Pulley Holding Tool



Inspection Procedure
Perform the following before disassembling the axle:
  • Remove the drain plug from the axle.
  • Drain the axle lubricant.
  • Inspect the oil and the case for metal chips. Determine the source of the metal chips, such as a broken gear or bearing cage.
  • Check the ring gear backlash. Refer to Backlash Inspection and Adjustment.

This information can be used in order to determine the cause of the axle problem.
The information will also help when setting up and preloading the differential case.
Determine the cause of the axle problem before disassembly, if possible.

Disassembly Procedure



1. Remove the upper differential carrier assembly bushing by performing the following steps:
    A. Install the J 36616-2 (1), the J 33791-1 (2), the thrust bearing (3), the J 21474-18 (4), and the forcing screw as shown.
    B. Remove the upper differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.



2. Remove the lower differential carrier assembly bushing by performing the following steps:
    A. Install the J 21474-18 (1), the thrust bearing (2), the J 33791-1 (3), the J 36616-2 (4), and the forcing screw as shown.
    B. Remove the lower differential carrier assembly bushing by holding the forcing screw and tightening the J 21474-18.




3. Remove the front axle actuator, S4WD axle only.
4. Disconnect the right side inner axle shaft from the differential side gear using a hammer and a brass drift, F4WD axle only.
5. Remove the inner axle shaft, F4WD axle only.
6. Remove the inner axle shaft housing to differential carrier assembly bolts.
7. Remove the inner axle shaft housing, F4WD axle only.
 


8. Carefully remove the inner axle shaft housing with the inner axle shaft and clutch fork components from the differential carrier assembly, S4WD axle only.



9. Remove the following components from the inner axle shaft housing:
    A. The clutch fork inner spring (10)
    B. The clutch fork assembly (11, 12, 13, 14)
    C. The clutch shaft shim (9)
    D. The clutch shaft sleeve (8)
    E. The front drive axle clutch gear (6) by doing the following:
        i. Clamp the inner axle shaft housing (4) in a vise. Clamp only on the mounting flange.
       ii. Strike the inside surface of the shaft (1) flange with a hammer and a brass drift in order to
          dislodge the front drive axle clutch gear (6) from the inner axle shaft (1).
     F. Remove the thrust washer (5).


 
10. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps:
      A. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing.
      B. Install the J 29369-1  (1) behind the inner axle shaft bearing.
      C. Install the J 2619-01  (2) to the J 29369-1  (1).
      D. Remove the inner axle shaft bearing and the seal using the J 2619-01 .



11. Remove the inner axle shaft bearing and the inner axle shaft seal by performing the following steps:
      A. Place the differential carrier assembly into a vise. Clamp only on the mounting flange of the differential carrier assembly case.
      B. Install the J 29369-1  (1) behind the inner axle shaft bearing.
      C. Install the J 2619-01  (2) to the J 29369-1 .
      D. Remove the inner axle shaft bearing and the inner axle shaft seal using the J 2619-01 .
12. Remove the differential carrier assembly from the vise.
13. Remove the front drive axle clutch shaft, S4WD axle only.
 


14. Use the J 34011 in order to remove the clutch shaft bearing, S4WD axle only.


 
15. Remove the vent connector.
 


16. Remove the differential carrier assembly bolts.
 


17. Separate the left carrier case half from the right carrier case half by tapping on the on the carrier case with a hammer and a
      brass drift.
18. Remove the differential case assembly. Disconnect the differential bearing adjuster nut locks from the differential bearing adjuster nut
      by prying up on the locks, S4WD axle - both sides, F4WD axle - left side.
 


19. Remove the differential bearing adjuster nuts and the differential bearing cups by doing the following, S4WD axle - both sides, F4WD
      axle - left side:
       A. Install the J 36599-A onto the differential bearing adjuster nut.
       B. Turn the J 36599-A clockwise in order to push the differential bearing adjuster nut and the bearing cup out of the bore.
20. Remove the differential bearing adjuster nut sleeves using a hammer and brass drift, S4WD axle - both sides, F4WD axle - left side.
 


21. Install the J 8614-01 as shown. Remove the pinion nut while holding the J 8614-01 .
22. Remove the washer.
 


23. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01  (1) as shown.
24. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1).
25. The steps below explain how to remove the drive pinion and pinion bearing cups using the J 36598 or the J 45765 and the J-45858 .
      Follow the appropriate steps depending on what tool is available.
26. Install the J 36598 into a vise.
 


27. Install the left differential carrier case half onto the J 36598 and the J 36598-6.
28. While holding the forcing screw of the J 36598 , turn the handle of the J 36598 counterclockwise in order to remove the pinion
      with the following components:
  • The pinion gear selectable shim
  • The inner pinion bearing
  • The collapsible spacer


 

29. Install the J 36598-5 (3) behind the inner pinion bearing cup.
30. Thread the forcing screw of the J 36598  (1) onto the J 36598-5 (3) until fully seated.
31. While holding the forcing screw of the J 36598  (1), turn the handle of the J 36598  (2) counterclockwise and press the inner
      bearing cup out from the differential carrier case.
 
 

32. Install the J 36598-5 (2) behind the outer pinion bearing cup.
33. Install the forcing screw of the J 36598  (1) to the J 36598-5 (2).
34. While holding the forcing screw of the J 36598 , turn the handle of the J 36598 clockwise in order to remove the
      following components:
  • The pinion oil seal
  • The pinion outer bearing
  • The pinion outer bearing cup


   

35. Install the J 45765 to the left side differential carrier case half over the drive pinion as shown.
36. Turn the forcing screw of the J 45765 clockwise to remove the following components from the left side differential carrier case half:
  • The drive pinion gear
  • The pinion gear selectable shim
  • The inner pinion bearing
  • The collapsible spacer

37. Remove the drive pinion seal using a suitable seal remover.
38. Remove the outer pinion bearing from the differential carrier case half.
 
 

39. Install the J 45858-4 over the inner pinion bearing cup.
 
 

40. Install the forcing screw (1) of the J 45858 into the J 45858-4 (2).
41. Drive out the inner pinion bearing cup by pounding on the forcing screw with a hammer.
 
 

42. Install the J 45858-3 (3), the thrust bearing and the washer (2), and the forcing screw (1) over the outer pinion bearing cup bore.



43. Install the J 45858-5 into the pinion bearing bore behind the outer pinion bearing cup. Slowly turn the forcing screw clockwise
      until the J 45858-5 is evenly seated behind the outer pinion bearing cup bore and the J 45858-3 is evenly seated over the outer
      pinion bearing cup bore.
44. Remove the outer pinion bearing cup by turning the forcing screw clockwise.
45. Remove the collapsible spacer from the drive pinion.
 


46. Install the J 22912-01 between the pinion bearing and the drive pinion.
47. Remove the inner pinion bearing using the J 22912-01 and a hydraulic press.
48. Remove the pinion gear selectable shim.
« Last Edit: 06/26/08 09:49 PM by ItsStopher » Logged
ItsStopher
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« Reply #1 on: 06/26/08 09:45 PM »

Differential Carrier Assembly - Assemble

Tools Required
  • J 8092 Universal Driver Handle - in - 10
  • J 8614-01 Flange and Pulley Holding Tool
  • J 35512 Inner Pinion Bearing Installer
  • J 36366 Pinion Oil Seal Installer
  • J 36599-A Side Bearing Nut Wrench
  • J 36603 Side Bearing Cup Installer
  • J 36609 Axle Tube Bearing Installer
  • J 36612 Output Shaft Bearing Installer
  • J 36614 Inner Pinion Bearing Installer
  • J 36615 Side Bearing Nut Wrench (9.25 inch axle)

1. Install the pinion bearing cups into the differential carrier assembly, if necessary. Refer to Pinion Bearing Cup Installation .
2. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.
 


3. Install the inner pinion bearing onto the pinion gear using the J 35512 , 8.25 inch axle, or the J 36614 , 9.25 inch axle.
4. Install the new collapsible spacer onto the pinion gear.
5. Install the outer pinion bearing into the differential carrier case half.
 


6. Install the pinion oil seal using J 36366 .
7. Install the pinion gear, with the inner pinion bearing and the new collapsible spacer, into the left differential carrier case half.
8. Apply sealant to the splines of the pinion yoke. Use the correct sealant.
9. Install the pinion yoke.

Notice
Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.


10. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show
      through the yoke.
11. Install the washer and a new pinion nut. If the new pinion nut cannot be installed, perform the following steps in order to
      seat the pinion yoke onto the pinion so that the washer and new pinion nut can be installed:
        A. Remove the pinion nut washer.
        B. Install the old pinion nut.
        C. Tighten the nut until a few of the shaft threads show through the nut so that the washer and new pinion nut can be installed.
        D. Remove the old pinon nut.
        E. Install the pinion nut washer.
        F. Install the new pinion nut.



12. Install the J 8614-01 onto the pinion yoke as shown.

Notice
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.


Important
If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.


13. Tighten the pinion nut while holding the J 8614-01.
   
      Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut in order
      to seat the bearings.

14. Remove the J 8614-01 .
15. Measure the rotating torque of the pinion using an inch-pound torque wrench.
 
     Specification
     The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings.

16. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15 lb in) for new bearings, reinstall
      the J 8614-01 and continue to tighten the pinion nut.

      Specification
      The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings.

17. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the
       rotating torque and adjust if necessary.
18. Remove the J 8614-01 .
19. Assemble the differential adjuster nut into the differential nut sleeve until fully seated, 8.25 inch axle - left and right sides.
 


20. Install the axle shaft bearings into the differential adjuster nut sleeve using the J 36612  (2) and the J 8092  (1), 8.25 inch
      S4WD axle - left and right sides, 8.25 inch F4WD axle - left side.
21. Install the axle shaft bearing into the differential adjuster nut sleeve using the J 36609 and the J 8092 , 9.25 inch axle - left side.
22. Install the differential adjuster nut assembly and new adjuster lock nut tabs into the differential carrier case using the J 36609
      and the J 8092, 8.25 inch axle - left and right sides.
23. Install the differential adjuster nut assembly into the differential carrier case, 9.25 inch axle - left side.
 


24. Install the differential case side bearing cups to the differential carrier case using the J 36603  (2) and the J 8092  (1),
      8.25 inch axle - left and right sides.
 


25. Install the differential case assembly into the left differential carrier case half.
 


26. Install the right differential carrier case half to the left differential carrier case half. Do not use sealer at this time. If the carrier
      case halves do not make complete contact, use the J 36599-A in order to back out the right differential adjuster nut sleeve
      until the differential carrier case halves make contact.
 


27. Install the differential carrier case bolts. Tighten the differential carrier case bolts to 47 Nm (35 lb ft).
28. Install the differential carrier assembly into a vise.
 


29. Turn the right side differential adjuster nut sleeve clockwise 1 revolutions using the J 36599-A .
 


30. For the 8.25 inch axle, turn the left side differential adjuster nut sleeve clockwise using the J 36599-A in order to preload the
      differential side bearings against the differential side bearing cups. Tighten the differential adjuster nut to 75 Nm (55 lb ft).



31. Rotate the pinion several times in order to seat the pinion and differential side bearings.
32. Measure the rotating torque of the drive pinion and differential assembly using an inch-pound torque wrench.

      Specification
      The rotating torque of the pinion and differential assembly should be 3.4-6.2 Nm (30-55 lb in) for new bearings or
      2.8-5.1 Nm (25-45 lb in) for used bearings.



33. If the rotating torque measurement is below 2.8 Nm (25 lb in) for used bearings, or 3.4 Nm (30 lb in) for new bearings, adjust the differential side
      bearing preload using the following steps:
      A. Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides.
      B. Using the J 36599-A or the J 36615 , turn the left and the right side differential adjuster nut sleeves in or clockwise one notch.
      C. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.
      D. Compare the new measurement to the specification listed in step 36, if the rotating torque of the pinion and differential
          assembly is not within specifications, continue to tighten the left and right side differential adjuster nut sleeves one notch
          at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
34. If the rotating torque measurement is above 5.1 Nm (45 lb in) for used bearings, or 6.2 Nm (55 lb in) for new bearings, adjust the
      differential side bearing preload using the following steps:
      A. Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides.
      B. Using the J 36599-A or the J 36615 , turn the left and the right side differential adjuster nut sleeves out or counterclockwise
          one notch.
      C. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.
      D. Compare the new measurement to the specification listed in step 36, if the rotating torque of the pinion and differential
          assembly is not within specifications, continue to loosen the left and right side differential adjuster nut sleeves one notch
          at a time on each side until the rotating torque of the pinion and differential assembly is within specifications
35. Once the specified rotating torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck
      the rotating torque and adjust if necessary.
35. Measure the drive pinion to ring gear backlash. Refer to Backlash Inspection and Adjustment .
« Last Edit: 06/26/08 09:55 PM by ItsStopher » Logged
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« Reply #2 on: 06/26/08 10:07 PM »

Backlash Inspection and Adjustment

Tools Required
  • J 8001 Dial Indicator Set
  • J 36599-A Side Bearing Nut Wrench
  • J 36615 Side Bearing Nut Wrench

1. Mark the location of the differential adjuster nut sleeves in relation to the differential carrier halves. Ensure that the notches
    can be counted when turned.
 


2. Install the J 8001-1 (1, 2), the J 8001-2 (3), and the J 8001-3 (4) as shown. Ensure that the button contacts the outer edge of
    the pinion yoke and that the plunger is at a right angle to the pinion yoke.
3. Move the pinion yoke back and forth through the pinion yoke's free play while not allowing the ring gear to move.
4. Record the dial indicator reading.
5. To determine the actual backlash, divide the dial indicator reading by 2. An actual dial indicator reading of 0.16 mm
    (0.006 in) means that there is actually 0.08 mm (0.003 in) backlash.

    Specification
    The backlash between the ring gear and the drive pinion should be between 0.08-0.25 mm (0.003-0.010 in)
    with a preferred specification of 0.13-0.18 mm (0.005-0.007 in).


Important
When adjusting the backlash, observe the following:

  • Always turn the left and the right differential adjuster nut sleeves in equal amounts.
  • Turning the differential adjuster nut sleeves one notch will change the backlash about 0.08 mm  (0.003 in).


6. If the backlash is too small, increase the backlash by turning the left differential adjuster nut sleeve in one notch using
    the J 36599-A , 8.25 inch axle, or the J 36615 , 9.25 inch axle, and the right differential adjuster nut sleeve out one notch
    using the J 36599-A .
7. If the backlash is too large, decrease the backlash by turning the right differential adjuster nut sleeve in one notch using
    the J 36599-A and the left differential adjuster nut sleeve out one notch using the J 36599-A , 8.25 inch axle.
8. Recheck the backlash and adjust as necessary.
9. Recheck the rotating torque of the pinion and differential assembly and adjust as necessary.
10. Once the backlash and rotating torque of the pinion and differential assembly is correct, perform a gear tooth
      contact pattern check to ensure proper contact between the pinion and the ring gear.
      Pattern Inspection .
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