Differential Axle Housing: Service and Repair

Differential Housing Cleaning and Inspection

Differential Carrier





1. Clean the differential carrier in solvent.
2. Inspect for the following conditions:

* Damage to threaded bolt holes (1)
* Broken flanges (2)
* Restrictions within the internal oil passages
* Damaged case or cover sealing surfaces
* Damage to the O-ring seal grooves (3)
* Porosity




Differential Carrier Covers





1. Clean the covers in solvent.
2. Inspect the left side cover output shaft bushing (3) for damage or excessive wear.
Important: Replacing the left side cover bushing requires a NEW left side cover and a NEW bushing. Replacing only the bushing will result in a low press fit condition. Use new bushings where new covers are available without bushings installed.



3. Inspect the covers for the following conditions:

* Damage to the O-ring seal surface (1)
* Damage to the axle shaft oil seal bores (2)
* Restrictions within the internal oil passages
* Porosity
* Dents or damage to the exterior of the rear cover that may create interference with the pinion shaft





4. Inspect the pump assembly, some models, for damage. Pump should turn freely without noise.



Drive Pinion Cleaning and Inspection





1. Clean the pinion components in solvent.
2. Inspect for the following conditions:

* Damage to the nut threads or locking area (1)
* Worn or scored bearings (2)
* The pinion housing/cage (4) for damaged bolt holes, broken flanges, restrictions within the oil passages, worn or loose bearing races and/or race bores
* The pinion shaft (5) for damaged threads, worn splines, or worn or scored gear teeth
* The pump drive machining (6) for wear, some models