Differential Case and Ring Gear — Traction-Lok

Special Tool(s)

	2 Jaw Puller 205-D072 (D97L-4221-A) or equivalent
	Gauge, Differential Clutch 205-022 (T66L-4204-A)
	Gauge, Differential Clutch 205-135 (T80P-4946-A)
	Gauge, Differential Clutch 205-270 (T87T-4946-A)
	Installer, Differential Side Bearing 205-010 (T57L-4221-A2)
	Step Plate 205-D016 (D80L-630-5) or equivalent

Disassembly

All differentials

1. Remove the differential carrier. Refer to Differential Carrier in this section.

2. Remove and discard the 10 differential ring gear bolts.

3. NOTE: Care should be taken not to damage the differential ring gear bolt hole threads.

   Insert a punch in the differential ring gear bolt holes and drive the differential ring gear off.

4. NOTE: The differential flange and ring gear flange must be free of any old retaining compound. Failure to clean the surfaces can result in ring gear runout concerns.

   Clean all traces of the old retaining compound from the differential flange and the ring gear flange.
   • Use solvent and Scotch-Brite® pads to remove old material.

5. Using a 2 Jaw Puller and Step Plate, remove the 2 differential bearings.

6. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft.
   • Discard the differential pinion shaft lock bolt.

With differential S-type clutch spring

7. NOTE: Due to the spring tension, care must be used when removing the differential clutch spring.

   Remove the differential clutch spring.

8. Remove the differential gears.
   1. Remove the 2 differential pinion gears and 2 thrust washers.
   2. Remove the 2 differential side gear and clutch pack assemblies.

9. NOTE: Keep the differential clutch packs in order. Do not mix the differential clutch packs. The differential clutch packs must be reassembled in the same sequence.

   If equipped with a S-type clutch spring, remove the differential clutch packs and differential side gears and tag them RH and LH with the selective shim.
   • Clean and inspect the remaining components of the differential case for wear or damage and install new components as necessary.

Without differential S-type clutch spring

10. NOTE: Do not throw away the belleville washers. The bellville washers will be reused.

    Remove the differential gears.
    1. Remove the 2 differential pinion gears and 2 thrust washers.
    2. Remove the 2 differential side gear and clutch pack assemblies.
    3. Remove the 2 belleville washers.

11. NOTE: Keep the differential clutch packs in order. Do not mix the differential clutch packs. The differential clutch packs must be reassembled in the same sequence.

    Remove the differential clutch packs and differential side gears and tag them RH and LH with the selective shim.
    • Clean and inspect the remaining components of the differential case for wear or damage and install new components as necessary.

Assembly

All differentials

1. Using friction modifier, separate the plates and lubricate each steel clutch plate. Soak all the friction plates for no less than 15 minutes.

Without differential S-type clutch spring

2. NOTE: Do not mix the clutch plates, clutch discs or shim from one side with the other.

   Assemble the differential clutch packs on their respective differential side gear.

With differential S-type clutch spring

3. NOTE: Do not mix the clutch plates, clutch discs or shim from one side with the other.

   Assemble the differential clutch packs on their respective differential side gear.

All differentials

4. Place the base portion of the Differential Clutch Gauge in a vise. Install the differential side gear and differential clutch pack (without the shim) on the tool.

5. Position the Differential Clutch Gauge hand-tight on top of the differential clutch pack.

6. Install the Differential Clutch Gauge over the disc and differential clutch pack.

7. Install the nut.
   • Tighten to 6.7 Nm (60 lb-in).

8. NOTE: Selective shims shown are available as part of the clutch pack replacement kit.

   Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. Refer to the chart to determine the correct thickness clutch shim to use.
   
   

    Selective Shims

   Feeler Gauge Thickness	Part Number	Description
   0.072 - 0.080	EOAZ-4A324-G	0.025 inch
   0.081 - 0.085	EOAZ-4A324-H	0.030 inch
   0.086 - 0.090	EOAZ-4A324-C	0.035 inch
   0.091 - 0.095	EOAZ-4A324-D	0.040 inch
   0.096 - 0101	EOAZ-4A324-F	0.045 inch

   
   

9. Remove the Differential Clutch Gauge from the differential clutch pack and differential side gear assembly.

10. Install the shim(s) on the differential clutch pack and differential side gear assembly.

Without differential S-type clutch spring

11. Install the belleville washer on the clutch pack and side gear assembly with the concave side away from the clutch pack.

All differentials

12. Install the 2 differential side gear assemblies in the differential case.

13. Install the 2 differential pinion gear and differential pinion thrust washer assemblies in the differential case.

With differential S-type clutch spring

14. If equipped with a S-type clutch spring, using a soft-faced hammer, install the differential S-type clutch spring.

All differentials

15. NOTE: The pinion shaft may require to be tapped in with a soft-faced hammer.

    Install the differential pinion shaft and install a new bolt finger-tight without tightening into the loctite covered area of the bolt.

16. Using the Differential Side Bearing Installer, install the 2 differential bearings.

17. Apply a one-eighth inch bead of maximum strength retaining compound on the rear face of the ring gear in the pattern shown.

18. Position the differential ring gear and the differential case. Align the bolt holes by starting 2 new bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.

19. Install the 10 new differential ring gear bolts.
    • Tighten to 135 Nm (100 lb-ft).

20. Using the Differential Clutch Gauge, check the torque required to rotate one differential side gear.
    • Mount the differential assembly and Differential Clutch Gauge in a vise.
    • The initial minimum break-away torque, if original clutch plates are used, must be within specification. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary.

21. Install the differential carrier. Refer to Differential Carrier in this section.