REAR DIFFERENTIAL CARRIER ASSEMBLY(for DANA Made w/o Differential Lock) DISASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

The following procedures are for BD22 (w/o Differential Lock).

PROCEDURE


  1. SECURE REAR DIFFERENTIAL CARRIER ASSEMBLY


    1. B003KY5

      Secure the rear differential carrier assembly.

  2. INSPECT REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. B003J87C01
      *a 36 mm (1.42 in.)

      Using a dial indicator, measure the runout of the companion flange vertically and laterally.

      Maximum Runout
      Runout Maximum
      Vertical runout 0.10 mm (0.00394 in.)
      Lateral runout 0.10 mm (0.00394 in.)

      If the runout is more than the maximum, replace the companion flange.

  3. INSPECT DIFFERENTIAL RING GEAR BACKLASH


    1. B003L2Q

      Using a dial indicator, measure the backlash of the differential ring gear.

      Standard backlash
      0.13 to 0.20 mm (0.00512 to 0.00787 in.)

      • If the backlash is not within the specification, adjust the side bearing preload or perform repairs as necessary.

        Tech Tips

        Perform the measurement at 3 or more positions around the circumference of the ring gear.

  4. INSPECT TOTAL PRELOAD


    1. B003NR2

      Using a torque wrench, measure the preload with the teeth of the differential drive pinion and differential ring gear in contact.

      Standard Total Preload
      Reduction Ratio Specified Condition
      3.909 2.25 to 4.24 N*m (23 to 43 kgf*cm, 20 to 37 in.*lbf)
      4.300 2.23 to 4.19 N*m (23 to 42 kgf*cm, 20 to 37 in.*lbf)
      4.555 2.21 to 4.16 N*m (23 to 42 kgf*cm, 20 to 36 in.*lbf)

      If the result is not as specified, adjust the preload.

  5. REMOVE REAR DRIVE PINION NUT


    1. B003JCTN01

      Using a chisel and hammer, stake the rear drive pinion nut.

      SST
      09930-00010   ( 09931-00010, 09931-00020 )
    2. B003M1BC01
      *a Turn
      *b Hold

      Using SST to hold the rear drive pinion companion flange sub-assembly with dust deflector in place, remove the rear drive pinion nut.

      SST
      09330-00021   ( 09330-00030 )

  6. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY WITH DUST DEFLECTOR


    1. B003K3YC01
      *a Turn
      *b Hold

      Using SST, remove the rear drive pinion companion flange sub-assembly with dust deflector.

      SST
      09950-40011   ( 09951-04010, 09953-04020, 09954-04010, 09955-04061 )

      Note

      Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

  7. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL


    1. B003K7AC01
      *1 Rear Differential Carrier Oil Seal
      *2 Rear Differential Drive Pinion Oil Slinger

      Using SST, remove the rear differential carrier oil seal.

      SST
      09308-10010

  8. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER


    1. B003MAL

      Remove the rear differential drive pinion oil slinger from the differential drive pinion.

  9. REMOVE DIFFERENTIAL BEARING CAP


    1. B003S2TC01
      *a Matchmark

      Place matchmarks on the differential bearing cap and differential carrier.

    2. Remove the 4 bolts and 2 differential bearing caps.

    3. Remove the 2 plate washers.

      B003JOJC01
      *a LH Side (Back Side) *b RH Side (Teeth Side)

      Tech Tips


      • Put identification marks on the plate washers to show the location for installation (LH side (back side) or RH side (teeth side)), or keep them separate so that they can be distinguished.

      • Measure the thickness of each plate washers and note it.

  10. REMOVE DIFFERENTIAL CASE ASSEMBLY


    1. B003KGT

      Remove the differential case assembly from the differential carrier.

      Tech Tips

      Tag the 2 rear differential case bearings (outer) so that they can be reinstalled in the correct locations.

  11. REMOVE DIFFERENTIAL DRIVE PINION


    1. B003SFE

      Using a press, remove the differential drive pinion with rear differential drive pinion bearing spacer from the differential carrier.

      Note

      Do not drop the differential drive pinion.

  12. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER


    1. B003K6E

      Remove the rear differential drive pinion bearing spacer from the differential drive pinion.

  13. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B003QELN01

      Using SST and a press, press out the rear drive pinion rear tapered roller bearing (inner) from the differential drive pinion.

      SST
      09555-55010

      Note

      Do not drop the differential drive pinion.

      Tech Tips

      If the differential drive pinion or differential ring gear is damaged, replace them as a set.

  14. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B003MO4

      Remove the rear drive pinion front tapered roller bearing (inner) from the differential carrier.

  15. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING


    1. B003K1CC01
      *1 Rear Drive Pinion Front Tapered Roller Bearing (Outer)

      Using SST, remove the rear drive pinion front tapered roller bearing (outer) from the differential carrier.

      SST
      09308-00010

  16. REMOVE DIFFERENTIAL OIL STORAGE RING


    1. B003MTMC01
      *1 Differential Oil Storage Ring

      Using SST and a hammer, tap out the differential oil storage ring from the differential carrier.

      SST
      09316-60011   ( 09316-00011 )

  17. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING


    1. B003KJ8

      Using a brass bar and hammer, tap out the rear drive pinion rear tapered roller bearing (outer) and adjust shim from the differential carrier.

      If the bearing is damaged during removal, replace it.

  18. REMOVE DIFFERENTIAL RING GEAR


    1. B003MXRC01
      *a Matchmark

      Place matchmarks on the differential ring gear and differential case.

    2. Remove the 12 differential ring gear set bolts.

    3. B003J7K

      Using a plastic-faced hammer, tap on the differential ring gear to remove it from the differential case.

  19. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT

    Tech Tips

    If the ring gear runout is within the specified value (refer to the "Inspect Runout of Differential Ring Gear" procedure above), skip this step.


    1. Install the rear differential case bearings (outer) to the differential case.

    2. Install the differential case assembly to the differential carrier.

    3. Install the 2 plate washers.

    4. Install the 2 differential bearing caps to the differential carrier with the 4 bolts.

      Torque:
      140 N*m  { 1428 kgf*cm, 103 ft.*lbf }
    5. B003MW3C01
      *a 92 mm (3.86 in.)

      Using a dial indicator, measure the differential case runout.

      Maximum runout
      0.07 mm (0.00276 in.)

    6. Remove the 4 bolts and 2 differential bearing caps.

    7. Remove the 2 plate washers.

    8. Remove the differential case assembly.

    9. Remove the rear differential case bearings (outer).

  20. REMOVE REAR DIFFERENTIAL CASE BEARING


    1. B003MO0C01
      *a Turn
      *b Hold

      Using SST, remove the 2 rear differential case bearings (inner) from the differential case.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09958-04011 )
      09950-60010   ( 09951-00360 )

      Tech Tips

      Do not remove the rear differential case bearings (inner) when not replacing the differential case assembly.

  21. DISASSEMBLE DIFFERENTIAL CASE


    1. B003MIU

      Using a chisel and hammer, unstake the differential case.

    2. B003PT1

      Using a pin punch and hammer, tap out the straight pin.

    3. B003QEM

      Remove the following parts from the differential case.


      1. B003S4IC04
        *1 Side Gear
        *2 Rear No. 1 Differential Side Gear Thrust Washer
        *3 Pinion Shaft
        *4 Pinion Gear
        *5 Pinion Gear Thrust Washer

        Side gear (2 pieces)

      2. Rear No. 1 differential side gear thrust washer (2 pieces)

      3. Pinion shaft

      4. Pinion gear (2 pieces)

      5. Pinion gear thrust washer (2 pieces)

  22. INSPECT DIFFERENTIAL GEAR KIT


    1. Check that the differential pinion and differential side gear are not damaged.

      If the differential pinion or differential side gear is damaged, replace the differential gear kit.

  23. INSPECT DIFFERENTIAL CASE


    1. Check that the differential case is not damaged.

      If the differential case is damaged, replace it.