Specifications
31
Prepare Parts for Reassembly
MAINTENANCE MANUAL
CAUTION
A THRUST WASHER, DIFFERENTIAL SIDE
GEAR AND PINION GEAR ARE MACHINED
AS A MATCHED SET. WHEN YOU REPLACE
ANY OF THESE PARTS, YOU MUST IN-
STALL A NEW MATCHED SET. DO NOT MIX
OLD AND NEW PARTS. DAMAGE TO COM-
PONENTS CAN RESULT.
3. Inspect the following main differential as-
sembly parts for wear or stress. Replace
parts that are damaged. Figure 4.7.
• Insidesurfacesofbothcasehalves
• Bothsurfacesofallthrustwashers
• Thefourtrunnionendsoftheu-jointofdifferential
• Teeth and splines of both differential side
gears
• Teethandboreofalldifferentialpinions
A. Remove the breather plug from the axle
housing.
B. Clean the breather plug.
• If the breather plug remains dirty after
cleaning:Replace the breathe plugr.
C. Apply compressed air to the breather.
• Ifcompressedairdoesnotpassthroughthe
breather plug: Replace the breather plug.
D. Install the breather plug in the axle housing.
Repair or Replace Parts
NOTE:
Threads must be without damage and clean
so that accurate adjustments and correct
torque values can be applied to fasteners
and parts.
1. Replace any fastener if the corners of the
head are worn.
2. Replace the washers if damaged.
3. Replace the gaskets, oil seals or grease seals
at the time of axle or differential repair.
4. Clean the parts and apply new silicone gas-
ket material where required when the axle or
differential is assembled. Figure 4.8.
4. Inspect the axle shafts for wear and cracks at
theange,shaftandsplines.Replacetheaxle
shafts, if necessary.
5. Inspect the breather plug.
5. Remove nicks, mars and burrs from parts
withmachinedorgroundsurfaces.Useane
le,indiastone,emeryclothorcrocuscloth.
6. Clean and repair the threads of fasteners and
holes.
Figure 4.7
Figure 4.8
DIFFERENTIAL
GEAR NEST
ASSEMBLY
SIDE GEAR
AND THRUST
WASHER
Inspect inside
surfaces.
Inspect.
Inspect.
Inspect.
PINION AND
THRUST WASHER
SPIDER OR
CROSS
DIFFERENTIAL
CASE HALVES
Remove silicone
gasket from parts.