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(27) Remove the b e a r i n g cap bolts and remove the
differential case f r o m t h e differential housing.
(28) Rotate the differential side gears u n t i l the dif-
ferential p i n i o n gears are located at the differential
case opening and remove t h e m .
(29) Remove t h e differential side gears a n d the
t h r u s t washers.
(30) Remove the differential bearings from t h e case
hubs. For differential cases w i t h 8 3/8-inch diameter
r i n g gears, use Tool C-293-PA w i t h Adapter Tools C-
293-48 a n d P l u g Tool SP-3289. For differential cases
w i t h 9 1/4-inch diameter r i n g gears, use Tool C-293-
PA w i t h Adapter Tools C-293-47 and P l u g Tool C-
293-3 (Fig. 23).
Fig. 23 Differential Bearing Removal
CLEANING/INSPECTION
(1) Wash and clean a l l the differential components
w i t h a n appropriate; cleaning solvent and, w i t h t h e
e x c e p t i o n
o f t h e b e a r i n g s ,
d r y t h e m w i t h
com-
pressed a i r . To clean the axle shaft tubes, insert a
stiff w i r e i n t o each tube, attach a clean c l o t h to the
wire a t the differential housing opening a n d w i t h -
draw t h e w i r e w i t h t h e cloth f r o m housing o u t w a r d
to the end of the tube.
(2) A l l the machined contact surfaces i n t h e differ-
ential housing and t h e differential b e a r i n g
caps
should be smooth and w i t h o u t any raised edges. The
drive p i n i o n gear shaft front and rear b e a r i n g cup
bores (machined surfaces) should also be smooth. I f
applicable, the raised m e t a l on the bore
shoulders
caused b y removal of t h e bearing cups should be flat-
tened w i t h a " f l a t nose" punch.
(3) The axle shaft seal contact surfaces located at
each outer end of the axle shaft tubes should be
smooth and w i t h o u t any r u s t and corrosion. T h i s also
applies to the brake support plate and the axle tube
flange
m a t i n g surface.
(4) The bearing contact surfaces on t h e axle shafts
and the axle shaft bearing rollers should be cleaned
and inspected for " p i t t i n g " , " s p a l l i n g " and other vis-
ible damage. I f either the shaft or t h e bearing is
damaged, discard both of t h e m and o b t a i n replace-
ment components.
N e v e r r e u s e a n a x l e s h a f t b e a r i n g a f t e r i t h a s
b e e n r e m o v e d
from
a n a x l e s h a f t t u b e .
(5) The axle shaft splines should be smooth and
w i t h o u t any excessive wear. The seal contact sur-
faces on t h e axle shaft should be smooth and w i t h o u t
any nicks, scratches or blemishes.
P o l i s h t h e a x l e s h a f t w i t h N o . 600 c r o c u s c l o t h
t o r e m o v e s l i g h t s u r f a c e d a m a g e w i t h o u t r e d u c -
i n g t h e d i a m e t e r o f t h e a x l e s h a f t seal
c o n t a c t
s u r f a c e .
(6) The differential bearings and the drive p i n i o n
gear shaft front and rear bearings and cups should
have smooth surfaces w i t h no broken or dented areas
on the rollers or the roller contact surfaces. The bear-
i n g cages m u s t not be distorted or cracked.
W h e n r e p l a c i n g a d r i v e p i n i o n g e a r b e a r i n g ,
a l w a y s
r e p l a c e t h e b e a r i n g a n d t h e c u p as a
" m a t c h e d s e t " o n l y .
(7) Inspect the r i n g gear and the drive p i n i o n gear
shaft gear for w o r n and chipped teeth, and damaged
a t t a c h i n g bolt threads. I f r e p l a c e m e n t
is neces-
s a r y , r e p l a c e b o t h t h e r i n g g e a r a n d t h e d r i v e
p i n i o n g e a r s h a f t as a " m a t c h e d s e t " o n l y .
(8) Inspect the drive p i n i o n gear shaft (axle) yoke
for cracks, w o r n splines, and w o r n seal contact sur-
face. Repair or replace the drive p i n i o n gear shaft
(axle) yoke as necessary.
(9) Inspect the drive p i n i o n gear shaft bearing "pre-
load" torque s h i m for damage and d i s t o r t i o n . Replace
i t i f necessary.
(10) The differential side gears and p i n i o n gears
should have smooth teeth and a u n i f o r m contact pat-
t e r n w i t h o u t excessive wear or broken surfaces. The
differential side gear h u b surfaces and t h r u s t washer
contact surfaces should be smooth and w i t h o u t any
scoring or m e t a l deposits.
(11) The machined t h r u s t washer contact surfaces
inside t h e differential case should be polished and
w i t h o u t any surface i r r e g u l a r i t i e s . The p i n i o n gear
mate shaft bore i n the differential case should be
round a n d w i t h o u t excessive wear f r o m t h e shaft con-
tact surfaces.
The
differential
p i n i o n gear bores
should also be r o u n d and w i t h o u t excessive wear
from t h e shaft contact surfaces.
(12) Inspect the axle shaft C-clip "locks" for cracks
and wear. Replace t h e m i f necessary.
(13) Test each threaded adjuster to determine i f i t
rotates freely. I f an adjuster binds, either repair the
damaged threads or replace the adjuster, as neces-
sary, to ensure t h a t the threaded w i l l adjusters ro-
tate freely.
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