Differential Case and Drive Pinion

Tools Required:

• Pinion Bearing Cone Replacer T53T-4621-C
• Differential Side Bearing Replacer T57L-4221-A1
• Companion Flange Remover T65L-4851-B
• Differential Side Bearing T70P-4221-A
• Pinion Bearing Cone Remover T71P-4621-B
• Companion Flange Holding Tool T78P-4851-A
• Step Plate T81P-4220-A

Removal

1. Raise vehicle and place jackstands under rear frame crossmember. Refer to Section 00-02. Lower the hoist so that axle is at suitable working height.

2. Remove cover from carrier and drain lubricant.

3. Perform the inspection before disassembly. Refer to Cleaning and Inspection .

4. Remove rear wheels and brake drums.

5. Working through cover opening, remove pinion shaft lock bolt and remove pinion shaft and pinion gears.
   
   
   
   

6. Push axle shaft inward until C-locks at button end of the shaft are clear of side gear recess.

    CAUTION: Care should be taken not to damage wheel seals when removing axle shafts from axle housing. In addition, axle shafts should be completely removed from axle housing.

7. Remove C-locks and pull axle shafts out of the housing.
   
   
   
   

8. Make scribe marks on driveshaft, yoke and rear axle companion flange to ensure proper alignment at assembly. Disconnect driveshaft from circular companion flange. Remove driveshaft from vehicle. Insert an oil seal replacement tool in the transmission extension housing to prevent leakage.
   
   
   
   

    CAUTION: Bearing caps must be installed in their original positions.

9. Mark one differential bearing cap to help position the caps properly during assembly.
   
   
   
   

10. Loosen differential bearing cap bolts and bearing caps.

    Note direction of arrows on bearing caps. When reassembled, the arrows must be pointing in the same direction as before removal.

11. Pry differential case, bearing cups and shims out until they are loose in the bearing caps. Remove bearing caps and remove differential assembly from carrier. Mark the cups and shims RH and LH to prevent assembly mix-up.
    
    
    
    

12. Inspect the differential bearings and cups for damage. If they are worn, pitted, galled or spalled, remove the differential bearings using Differential Side Bearing Remover T70P-4221-A and step plate T81P-4220-A. Install new bearings using Differential Side Bearing Replacer T57L-4221-A1.
    
    
    
    
    
    
    
    

13. Mark circular companion flange in relation to the pinion shaft. Hold the rear axle companion flange with Companion Flange Holding Tool T78P-4851-A and remove the pinion nut. If a new gearset is being installed, the circular companion flange need not be marked.
    
    
    
    
    
    
    
    

     CAUTION: Never use a hammer to remove the companion flange.

14. Remove the circular companion flange with Companion Flange Remover T65L-4851-B.
    
    
    
    

15. With a soft-faced hammer, drive pinion out of front bearing cone and remove through rear of carrier.

     CAUTION: Do not damage housing while removing seal.

16. Position screwdriver under flange of pinion seal and strike with hammer to wedge screwdriver blade between metal flange of pinion seal and differential housing.
    
    
    
    

17. Pry up on metal flange of pinion seal. Install gripping pliers and strike with hammer until pinion seal is removed.
    
    
    
    

18. To remove and install the pinion rear cone and roller assembly, use Pinion Bearing Cone Remover T71P-4621-B and Pinion Bearing Cone Replacer T53T-4621-C.
    
    
    
    
    
    
    
    

19. Measure the shim(s), found under bearing cone, with a micrometer and record thickness.