Jeep Cherokee (XJ): Service procedures. Removal and installation. Disassembly and assembly

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Differential and driveline > 8 1/4 Rear axle > Service procedures. Removal and installation. Disassembly and assembly

Service procedures

LUBRICANT CHANGE

(1) Raise and support the vehicle.

(2) Remove the lubricant fill hole plug from the differential housing cover.

(3) Remove the differential housing cover and drain the lubricant from the housing.

(4) Clean the housing cavity with a flushing oil, light engine oil, or lint free cloth. Do not use water, steam, kerosene, or gasoline for cleaning.

(5) Remove the original sealant from the housing and cover surfaces.

(6) Apply a bead of Mopart Silicone Rubber Sealant, or equivalent, to the housing cover (Fig. 7).

Fig. 7 Apply Sealant
Fig. 7 Apply Sealant

1 - SEALANT
2 - AXLE HOUSING COVER

Install the housing cover within 5 minutes after applying the sealant.

(7) Install the cover and any identification tag.

Tighten the cover bolts to 41 N·m (30 ft. lbs.) torque.

(8) For Trac-loky differentials, a quantity of Mopart Trac-loky lubricant (friction modifier), or equivalent, must be added after repair service or a lubricant change. Refer to the Lubricant Specifications section of this group for the quantity necessary.

(9) Fill differential with Mopart Hypoid Gear Lubricant, or equivalent, to bottom of the fill plug hole. Refer to the Lubricant Specifications section of this group for the quantity necessary.

CAUTION: Overfilling the differential can result in lubricant foaming and overheating.

(10) Install the fill hole plug and lower the vehicle.

(11) Trac-loky differential equipped vehicles should be road tested by making 10 to 12 slow figureeight turns. This maneuver will pump the lubricant through the clutch discs to eliminate a possible chatter noise complaint.

Removal and installation

Rear axle

REMOVAL

(1) Raise and support the vehicle.

(2) Position a suitable lifting device under the axle.

(3) Secure axle to device.

(4) Remove the wheels and tires.

(5) Secure brake drums to the axle shaft.

(6) Disconnect the brake hose at the axle junction block. Do not disconnect the brake hydraulic lines at the wheel cylinders. Refer to Group 5, Brakes, for proper procedures.

(7) Disconnect the parking brake cables and cable brackets.

(8) Disconnect the vent hose from the axle tube.

(9) Mark the propeller shaft and yoke for installation alignment reference.

(10) Remove propeller shaft.

(11) Disconnect shock absorbers from axle.

(12) Remove the stabilizer links.

(13) Remove the spring clamps and spring brackets.

Refer to Group 2, Suspension, for proper procedures.

(14) Separate the axle from the vehicle.

INSTALLATION

(1) Raise the axle with lifting device and align to the leaf spring centering bolts.

(2) Install the spring clamps and spring brackets.

Refer to Group 2, Suspension, for proper procedures.

(3) Install shock absorbers and tighten nuts to 60 N·m (44 ft. lbs.) torque.

(4) Install the stabilizer links. Tighten sway bar links to 74 N·m (55 ft. lbs.).

(5) Connect the parking brake cables and cable brackets.

(6) Install the brake drums. Refer to Group 5, Brakes, for proper procedures.

(7) Connect the brake hose to the axle junction block. Refer to Group 5, Brakes, for proper procedures.

(8) Install axle vent hose.

(9) Align propeller shaft and pinion yoke reference marks. Install universal joint straps and bolts.

Tighten to 19 N·m (14 ft. lbs.) torque.

(10) Install the wheels and tires.

(11) Add gear lubricant, if necessary. Refer to Lubricant Specifications in this section for lubricant requirements.

(12) Remove lifting device from axle and lower the vehicle.

Axle shaft

REMOVAL

(1) Raise and support vehicle. Ensure that the transmission is in neutral.

(2) Remove wheel and tire assembly.

(3) Remove brake drum. Refer to Group 5, Brakes, for proper procedure.

(4) Clean all foreign material from housing cover area.

(5) Loosen housing cover bolts. Drain lubricant from the housing and axle tubes. Remove housing cover.

(6) Rotate differential case so that pinion mate shaft lock screw is accessible. Remove lock screw and pinion mate shaft from differential case (Fig. 8).

Fig. 8 Pinion Mate Shaft Lock Screw
Fig. 8 Pinion Mate Shaft Lock Screw

1 - LOCK SCREW
2 - PINION MATE SHAFT

(7) Push axle shaft inward and remove axle shaft C-lock from the axle shaft (Fig. 9).

(8) Remove axle shaft. Use care to prevent damage to axle shaft bearing and seal, which will remain in axle tube.

(9) Inspect axle shaft seal for leakage or damage.

(10) Inspect roller bearing contact surface on axle shaft for signs of brinelling, galling and pitting. If any of these conditions exist, the axle shaft and/or bearing and seal must be replaced.

INSTALLATION

(1) Lubricate bearing bore and seal lip with gear lubricant. Insert axle shaft through seal, bearing, and engage it into side gear splines.

NOTE: Use care to prevent shaft splines from damaging axle shaft seal lip.

Fig. 9 Axle Shaft C-Lock
Fig. 9 Axle Shaft C-Lock

1 - C-LOCK
2 - AXLE SHAFT
3 - SIDE GEAR

(2) Insert C-lock in end of axle shaft. Push axle shaft outward to seat C-lock in side gear.

(3) Insert pinion shaft into differential case and through thrust washers and differential pinions.

(4) Align hole in shaft with hole in the differential case and install lock screw with Loctitet on the threads. Tighten lock screw to 11 N·m (8 ft. lbs.) torque.

(5) Install cover and add fluid. Refer to Lubricant Change procedure in this section for procedure and lubricant requirements.

(6) Install brake drum. Refer to Group 5, Brakes, for proper procedures.

(7) Install wheel and tire.

(8) Lower vehicle.

Axle seal and bearing

REMOVAL

(1) Remove axle shaft.

(2) Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 10).

NOTE: The seal and bearing can be removed at the same time with the bearing removal tool.

(3) Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310, using Adapter Foot 6310-9 (Fig. 11).

INSTALLATION

NOTE: Do not install the original axle shaft seal.

Always install a new seal.

(1) Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube.

Fig. 10 Axle Seal Removal
Fig. 10 Axle Seal Removal

1 - AXLE TUBE
2 - AXLE SEAL
3 - PRY BAR

Fig. 11 Axle Shaft Bearing Removal Tool
Fig. 11 Axle Shaft Bearing Removal Tool

1 - NUT
2 - GUIDE PLATE
3 - GUIDE
4 - THREADED ROD
5 - ADAPTER
6 - FOOT
7 - AXLE TUBE

(2) Install the axle shaft bearing with Installer C-4198 and Handle C-4171 (Fig. 12). Ensure that the bearing part number is against the installer. Verify that the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing.

(3) Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the axle tube, the seal is installed to the correct depth.

(4) Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft.

(5) Install the axle shaft.

Fig. 12 Axle Shaft Seal and Bearing Installation
Fig. 12 Axle Shaft Seal and Bearing Installation

1 - HANDLE
2 - INSTALLER
3 - AXLE TUBE

Pinion seal

REMOVAL

(1) Raise and support the vehicle.

(2) Scribe a mark on the universal joint, pinion yoke, and pinion shaft for reference.

(3) Disconnect the propeller shaft from the pinion yoke. Secure the propeller shaft in an upright position to prevent damage to the rear universal joint.

(4) Remove the wheel and tire assemblies.

(5) Remove the brake drums to prevent any drag.

The drag may cause a false bearing preload torque measurement.

(6) Rotate the pinion yoke three or four times.

(7) Measure the amount of torque necessary to rotate the pinion gear with a (in. lbs.) dial-type torque wrench. Record the torque reading for installation reference.

(8) Hold the yoke with Wrench 6719. Remove the pinion nut and washer.

(9) Remove the yoke with Remover C-452 (Fig. 13).

(10) Remove the pinion seal with suitable pry tool or slide-hammer mounted screw.

INSTALLATION

(1) Clean the seal contact surface in the housing bore.

(2) Examine the splines on the pinion shaft for burrs or wear. Remove any burrs and clean the shaft.

Fig. 13 Yoke Removal
Fig. 13 Yoke Removal

1 - PINION YOKE
2 - TOOL C452

(3) Inspect pinion yoke for cracks, worn splines and worn seal contact surface. Replace yoke if necessary.

NOTE: The outer perimeter of the seal is pre-coated with a special sealant. An additional application of sealant is not required.

(4) Apply a light coating of gear lubricant on the lip of pinion seal.

(5) Install the new pinion seal with Installer C-4076-B and Handle C-4735-1 (Fig. 14).

Fig. 14 8 1/4 Axle Pinion Seal Installation
Fig. 14 8 1/4 Axle Pinion Seal Installation

1 - SPECIAL TOOL C-4735
2 - DIFFERENTIAL HOUSING
3 - SPECIAL TOOL C-4076-A

NOTE: The seal is correctly installed when the seal flange contacts the face of the differential housing flange.

(6) Position the pinion yoke on the end of the shaft with the reference marks aligned.

(7) Seat yoke on pinion shaft with Installer C-3718 and Wrench 6719.

(8) Remove the tools and install the pinion yoke washer. The convex side of the washer must face outward.

CAUTION: Do not exceed the minimum tightening torque when installing the pinion yoke retaining nut at this point. Damage to collapsible spacer or bearings may result.

(9) Hold pinion yoke with Yoke Holder 6719 and tighten shaft nut to 285 N·m (210 ft. lbs.) (Fig. 15).

Rotate the pinion several revolutions to ensure the bearing rollers are seated.

Fig. 15 Tightening Pinion Nut
Fig. 15 Tightening Pinion Nut

1 - DIFFERENTIAL HOUSING
2 - YOKE HOLDER
3 - TORQUE WRENCH

(10) Rotate the pinion using an (in. lbs.) torque wrench. Rotating torque should be equal to the reading recorded during removal, plus an additional 0.56 N·m (5 in. lbs.) (Fig. 16).

CAUTION: Never loosen pinion nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated.

Fig. 16 Check Pinion Rotation Torque
Fig. 16 Check Pinion Rotation Torque

1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH

(11) If the rotating torque is low, use Yoke Holder 6719 to hold the pinion yoke (Fig. 15) and tighten the pinion nut in 6.8 N·m (5 ft. lbs.) increments until proper rotating torque is achieved.

NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition.

(12) The seal replacement is unacceptable if the final pinion nut torque is less than 285 N·m (210 ft.

lbs.).

(13) Install the propeller shaft with the installation reference marks aligned.

(14) Tighten the universal joint yoke clamp screws to 19 N·m (14 ft. lbs.).

(15) Install the brake drums.

(16) Install wheel and tire assemblies and lower the vehicle.

(17) Check the differential housing lubricant level.

Differential

REMOVAL

(1) Remove the axle shafts.

NOTE: Side play resulting from bearing races being loose on case hubs requires replacement of the differential case.

(2) Mark the differential housing and the differential bearing caps for installation reference (Fig. 17).

Fig. 17 Mark For Installation Reference
Fig. 17 Mark For Installation Reference

1 - INSTALLATION REFERENCE MARKS
2 - INSTALLATION REFERENCE MARKS
3 - DIFFERENTIAL HOUSING
4 - BEARING CAP

(3) Remove bearing threaded adjuster lock from each bearing cap. Loosen the bolts, but do not remove the bearing caps.

(4) Loosen the threaded adjusters with Wrench C-4164 (Fig. 18).

Fig. 18 Threaded Adjuster Tool
Fig. 18 Threaded Adjuster Tool

1 - AXLE TUBE
2 - BACKING PLATE
3 - TOOL C-4164

(5) Hold the differential case while removing bearing caps and adjusters.

(6) Remove the differential case.

NOTE: Each differential bearing cup and threaded adjuster must be kept with their respective bearing.

INSTALLATION

(1) Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups, and threaded adjusters. A dab of grease can be used to keep the adjusters in position. Carefully position the assembled differential case in the housing.

(2) Observe the reference marks and install the differential bearing caps at their original locations (Fig. 19).

Fig. 19 Bearing Caps & Bolts
Fig. 19 Bearing Caps & Bolts

1 - INSTALLATION REFERENCE MARKS
2 - INSTALLATION REFERENCE MARKS
3 - DIFFERENTIAL HOUSING
4 - BEARING CAP

(3) Install bearing cap bolts and tighten the upper bolts to 14 N·m (10 ft. lbs.). Tighten the lower bolts finger-tight until the bolt head is seated.

(4) Perform the differential bearing preload and adjustment procedure.

NOTE: Be sure that all bearing cap bolts are tightened to the final torque of 95 N·m (70 ft.lbs) before proceeding.

(5) Install axle shafts and differential housing cover.

Differential side bearings

REMOVAL

(1) Remove differential case from axle housing.

(2) Remove the bearings from the differential case with Puller/Press C-293-PA and Adapters C-293-48 and Plug SP-3289 (Fig. 20).

INSTALLATION

(1) Install differential side bearings. Use Installer C-4340 with handle C-4171 (Fig. 21).

(2) Install differential case in axle housing.

Fig. 20 Differential Bearing Removal
Fig. 20 Differential Bearing Removal

1 - SPECIAL TOOL C-293-PA
2 - SPECIAL TOOL C-293-48
3 - BEARING
4 - DIFFERENTIAL
5 - SPECIAL TOOL SP-3289

Ring gear

The ring gear and pinion are serviced in a matched set. Do not replace the ring gear without replacing the pinion.

REMOVAL

(1) Remove differential from axle housing.

(2) Place differential case in a suitable vise with soft metal jaw protectors. (Fig. 22).

(3) Remove bolts holding ring gear to differential case.

(4) Using a soft hammer, drive ring gear from differential case (Fig. 22).

INSTALLATION

CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage.

(1) Invert the differential case.

Fig. 21 Install Differential Side Bearings
Fig. 21 Install Differential Side Bearings

1 - HANDLE C-4171
2 - DIFFERENTIAL
3 - BEARING
4 - TOOL C-4340

Fig. 22 Ring Gear Removal
Fig. 22 Ring Gear Removal

1 - CASE
2 - RING GEAR
3 - RAWHIDE HAMMER

(2) Position ring gear on the differential case and start two ring gear bolts. This will provide case-toring gear bolt hole alignment.

(3) Invert the differential case in the vise.

(4) Install new ring gear bolts and alternately tighten to 102 N·m (75 ft. lbs.) torque (Fig. 23).

(5) Install differential in axle housing and verify gear mesh and contact pattern.

Fig. 23 Ring Gear Bolt Installation
Fig. 23 Ring Gear Bolt Installation

1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE

Pinion gear

The ring gear and pinion are serviced in a matched set. Do not replace the pinion without replacing the ring gear.

REMOVAL

(1) Remove differential from the axle housing.

(2) Mark pinion yoke and propeller shaft for installation alignment.

(3) Disconnect propeller shaft from pinion yoke.

Using suitable wire, tie propeller shaft to underbody.

(4) Using Yoke Holder 6719 to hold yoke and remove the pinion yoke nut and washer.

(5) Using Remover C-452, remove the pinion yoke from pinion shaft (Fig. 24).

(6) Partially install pinion nut onto pinion to protect the threads.

(7) Remove the pinion from housing (Fig. 25).

Catch the pinion with your hand to prevent it from falling and being damaged.

(8) Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw.

(9) Remove oil slinger, if equipped, and front pinion bearing.

(10) Remove the front pinion bearing cup with Remover C-4345 and Handle C-4171 (Fig. 26).

(11) Remove the rear bearing cup from housing (Fig. 27). Use Remover C-4307 and Handle C-4171.

Fig. 24 Pinion Yoke Removal
Fig. 24 Pinion Yoke Removal

1 - PINION YOKE
2 - TOOL C452

Fig. 25 Remove Pinion Gear
Fig. 25 Remove Pinion Gear

1 - RAWHIDE HAMMER

(12) Remove the collapsible preload spacer (Fig. 28).

(13) Remove the rear bearing from the pinion (Fig.

29) with Puller/Press C-293-PA and Adapters C-293-47.

Place 4 adapter blocks so they do not damage the bearing cage.

(14) Remove the depth shims from the pinion shaft. Record the thickness of the depth shims.

INSTALLATION

(1) Apply Mopart Door Ease, or equivalent, stick lubricant to outside surface of bearing cup.

(2) Install the pinion rear bearing cup (Fig. 30) with Installer C-4308 and Driver Handle C-4171.

Fig. 26 Front Bearing Cup Removal
Fig. 26 Front Bearing Cup Removal

1 - REMOVER
2 - HANDLE

Fig. 27 Rear Bearing Cup Removal
Fig. 27 Rear Bearing Cup Removal

1 - DRIVER
2 - HANDLE

(2) Ensure cup is correctly seated.

(3) Apply Mopart Door Ease, or equivalent, stick lubricant to outside surface of bearing cup.

(4) Install the pinion front bearing cup (Fig. 31) with Installer D-130 and Handle C-4171.

(5) Install pinion front bearing, and oil slinger, if equipped.

Fig. 28 Collapsible Spacer
Fig. 28 Collapsible Spacer

1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING

Fig. 29 Rear Bearing Removal
Fig. 29 Rear Bearing Removal

1 - SPECIAL TOOL C-293-PA
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFT

(6) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1 (Fig. 32).

Fig. 30 Pinion Rear Bearing Cup Installation
Fig. 30 Pinion Rear Bearing Cup Installation

1 - INSTALLER
2 - HANDLE

Fig. 31 Pinion Front Bearing Cup Installation
Fig. 31 Pinion Front Bearing Cup Installation

1 - INSTALLER
2 - HANDLE

NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion head to achieve proper ring and pinion gear mesh. If the factory installed ring gear and pinion are reused, the pinion depth shim should not require replacement.

If required, refer to Pinion Gear Depth to select the proper thickness shim before installing rear pinion bearing.

(7) Place the proper thickness depth shim on the pinion.

Fig. 32 Pinion Seal Installation
Fig. 32 Pinion Seal Installation

1 - SPECIAL TOOL C-4735
2 - DIFFERENTIAL HOUSING
3 - SPECIAL TOOL C-4076-A

(8) Install the rear bearing and slinger, if equipped, on the pinion (Fig. 33) with Installer 6448.

Fig. 33 Shaft Rear Bearing Installation
Fig. 33 Shaft Rear Bearing Installation

1 - PRESS
2 - INSTALLATION TOOL
3 - DRIVE PINION
4 - DRIVE PINION SHAFT REAR BEARING

(9) Install a new collapsible preload spacer on pinion shaft and install pinion in housing (Fig. 34).

(10) Install pinion in housing.

(11) Install yoke with Installer C-3718 and Yoke Holder 6719.

(12) Install the yoke washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play. It will not be possible at this point to achieve zero bearing end-play if a new collapsible spacer was installed.

Fig. 34 Collapsible Preload Spacer
Fig. 34 Collapsible Preload Spacer

1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING

(13) Tighten the nut to 285 N·m (210 ft. lbs.).

CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated.

(14) Using Yoke Holder 6719, crush collapsible spacer until bearing end play is taken up.

(15) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 35).

(16) Check bearing rotating torque with an inch pound torque wrench (Fig. 35). The torque necessary to rotate the pinion gear should be:

  •  Original Bearings - 1 to 2 N·m (10 to 20 in. lbs.).
  •  New Bearings - 1 to 5 N·m (10 to 30 in. lbs.).

(17) Install propeller shaft.

(18) Install differential in housing.

Fig. 35 Check Pinion Rotating Torque
Fig. 35 Check Pinion Rotating Torque

1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH

Disassembly and assembly

Standard differential

DISASSEMBLY

(1) Remove pinion mate shaft lock screw (Fig. 36).

(2) Remove pinion mate shaft.

(3) Rotate the differential side gears and remove the differential pinion gears and thrust washers (Fig. 37).

Fig. 36 Pinion Mate Shaft Lock Screw
Fig. 36 Pinion Mate Shaft Lock Screw

1 - LOCK SCREW
2 - PINION MATE SHAFT

(4) Remove the differential side gears and thrust washers.

Fig. 37 Pinion Mate Gear Removal
Fig. 37 Pinion Mate Gear Removal

1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR

ASSEMBLY

(1) Install the differential side gears and thrust washers.

(2) Install the differential pinion gears and thrust washers.

(3) Install the pinion mate shaft.

(4) Align the hole in the pinion mate shaft with the hole in the differential case and install the pinion mate shaft lock screw.

(5) Lubricate all differential components with hypoid gear lubricant.

Trac-lok differential

The Trac-loky differential components are illustrated in (Fig. 38). Refer to this illustration during repair service.

DISASSEMBLY

(1) Clamp Side Gear Holding Tool 8138 in a vise.

(2) Position the differential case on Side Gear Holding Tool 8138 (Fig. 39).

(3) Remove ring gear, if necessary. Ring gear removal is necessary only if the ring gear is to be replaced. The Trac-loky differential can be serviced with the ring gear installed.

Fig. 38 Trac-lokY Differential Components
Fig. 38 Trac-lok Differential Components

1 - THRUST WASHER
2 - PINION
3 - SHAFT LOCK SCREW
4 - PINION MATE SHAFT
5 - SIDE GEAR
6 - RETAINER
7 - DISC
8 - CLUTCH PACK
9 - DIFFERENTIAL CASE
10 - RETAINER

Fig. 39 Differential Case Holding Tool
Fig. 39 Differential Case Holding Tool

1 - SIDE GEAR HOLDING TOOL
2 - VISE
3 - DIFFERENTIAL

(4) Remove the pinion mate shaft lock screw (Fig.

40).

Fig. 40 Mate Shaft Lock Screw
Fig. 40 Mate Shaft Lock Screw

1 - LOCK SCREW
2 - PINION MATE SHAFT

(5) Remove the pinion mate shaft. If necessary, use a drift and hammer (Fig. 41).

(6) Install and lubricate Step Plate 8140-2 (Fig.

42).

(7) Assemble Threaded Adapter 8140-1 into top side gear. Thread Forcing Screw 6960-4 into adapter until it becomes centered in adapter plate.

Fig. 41 Mate Shaft Removal
Fig. 41 Mate Shaft Removal

1 - PINION MATE SHAFT
2 - SIDE GEAR
3 - DRIFT
4 - PINION MATE GEAR

Fig. 42 Step Plate Tool Installation
Fig. 42 Step Plate Tool Installation

1 - SPECIAL TOOL 8140-2
2 - LOWER SIDE GEAR
3 - DIFFERENTIAL CASE

(8) Position a small screw driver in slot of Threaded Adapter 8140-1 (Fig. 43) to prevent adapter from turning.

(9) Tighten forcing screw tool 122 N·m (90 ft. lbs.) maximum to compress Belleville springs in clutch packs (Fig. 44).

(10) Using an appropriate size feeler gauge, remove thrust washers from behind the differential pinions (Fig. 45).

(11) Insert Turning Bar 6960-2 in case (Fig. 46).

Fig. 43 Threaded Adapter Installation
Fig. 43 Threaded Adapter Installation

1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - DISC 8140-2
5 - THREADED ROD C-6960-4
6 - THREADED ADAPTER DISC 8140-1

Fig. 44 Tighten Belleville Spring Compressor Tool
Fig. 44 Tighten Belleville Spring Compressor Tool

1 - TORQUE WRENCH
2 - TOOL ASSEMBLED
3 - DIFFERENTIAL CASE

(12) Loosen the Forcing Screw 6960-4 in small increments until the clutch pack tension is relieved and the differential case can be turned using Turning Bar 6960-2.

(13) Rotate differential case until the differential pinions can be removed.

Fig. 45 Remove Pinion Thrust Washer
Fig. 45 Remove Pinion Thrust Washer

1 - THRUST WASHER
2 - FEELER GAUGE

(14) Remove pinions from differential case.

Fig. 46 Pinion Gear Removal
Fig. 46 Pinion Gear Removal

1 - PINION GEARS
2 - TOOL

(15) Remove Forcing Screw 6960-4, Step Plate 8140-2, and Threaded Adapter 8140-1.

(16) Remove top side gear, clutch pack retainer, and clutch pack. Keep plates in correct order during removal (Fig. 47).

(17) Remove differential case from Side Gear Holding Tool 8138. Remove side gear, clutch pack retainer, and clutch pack. Keep plates in correct order during removal.

Fig. 47 Side Gear & Clutch Disc Removal
Fig. 47 Side Gear & Clutch Disc Removal

1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK

ASSEMBLY

NOTE: The clutch discs are replaceable as complete sets only. If one clutch disc pack is damaged, both packs must be replaced.

Lubricate each component with gear lubricant before assembly.

(1) Assemble the clutch discs into packs and secure disc packs with retaining clips (Fig. 48).

(2) Position assembled clutch disc packs on the side gear hubs.

(3) Install clutch pack and side gear in the ring gear side of the differential case (Fig. 49). Be sure clutch pack retaining clips remain in position and are seated in the case pockets.

(4) Position the differential case on Side Gear Holding Tool 8138.

(5) Install lubricated Step Plate 8140-2 in lower side gear (Fig. 50).

(6) Install the upper side gear and clutch disc pack (Fig. 50).

(7) Hold assembly in position. Insert Threaded Adapter 8140-1 into top side gear.

(8) Insert Forcing Screw 6960-4.

(9) Tighten forcing screw tool to slightly compress clutch discs.

Fig. 48 Clutch Disc Pack
Fig. 48 Clutch Disc Pack

1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER

Fig. 49 Clutch Discs & Lower Side Gear Installation
Fig. 49 Clutch Discs & Lower Side Gear Installation

1 - DIFFERENTIAL CASE
2 - LOWER SIDE GEAR AND CLUTCH DISC PACK

(10) Place differential pinions in position in side gears and verify that the pinion mate shaft holes are aligned.

(11) Rotate case with Turning Bar 6960-2 until the pinion mate shaft holes in the differential pinions align with holes in case. It may be necessary to slightly tighten the forcing screw in order to install the pinions.

Upper Side Gear & Clutch Disc Pack Installation
Fig. 50 Upper Side Gear & Clutch Disc Pack Installation

1 - UPPER SIDE GEAR AND CLUTCH DISC PACK
2 - DIFFERENTIAL CASE
3 - SPECIAL TOOL 8140-2

(12) Tighten forcing screw to 122 N·m (90 ft. lbs.) maximum to compress the Belleville springs.

(13) Lubricate and install thrust washers behind pinions and align washers with a small screw driver.

Insert mate shaft into each pinion to verify alignment.

(14) Remove Forcing Screw 6960-4, Step Plate 8140-2, and Threaded Adapter 8140-1.

(15) Install pinion mate shaft and align holes in shaft and case.

(16) Install the pinion mate shaft lock screw finger tight to hold shaft during differential installation.

(17) Lubricate all differential components with hypoid gear lubricant.

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