Differential Case: Service and Repair

Differential Case Cleaning and Inspection

Differential Case





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

* Cracks or other damage
* Damage to threaded bolt holes
* Unusual wear, scoring, or grooves in the clutch pack area
* Scored or damaged case side bearing mounting flanges




Gears and Shafts





1. Clean the gears and shafts with solvent.
2. Inspect the gears for the following conditions:

* Chips or cracks
* Pitting
* Heat discoloration
* Unusual wear
* Excessive wear or scoring in the side gear (1) pin bores
* Wear, grooves, or scoring on the side gear pin
* Scored or worn side gear washers (2)
* Unusual wear or grooves on the output gear (3) splines
* Damaged to the ring gear threaded bolt holes
* Damage to the ring gear vehicle speed sensor reluctor ring lobes





3. Inspect the shafts for the following conditions:

* Unusual wear
* Grooved, worn, or damaged splines
* Damaged C-clip grooves




Clutch Discs and Plates





1. Clean the discs and plates with solvent.
2. Inspect the discs and plates for the following conditions:

* Unusual wear, scoring, or grooves on the separator plate friction surfaces (1)
* Friction plates with uneven wear or worn friction material (2)
If any one plate or disk in either the left or right pack show signs of wear or scoring replace the complete pack on both sides.
* Bent or warped plates or discs
Lay the plates and discs on a flat surface and inspect for warpage
* A worn, scored, or collapsed bellville washer (3)




Bearings and Races

Fatique Spalling:

1. Inspect the bearing rollers and cups for the following conditions:

* Pitting
* Scoring or grooves
* Excessive wear or other damage

Indentations:

2. Inspect the bearing rollers and cups for heat discoloration.
Heat discoloration ranges from a faint yellow to a dark blue color. This discoloration may result from an overload or improper lubrication. Excessive heat causes softening of the rollers and cups. Bearings or cups with sign of heat discoloration must be replaced.

Bent Cage:

3. Inspect for bent bearing cages.




4. Inspect for damaged bearing cages.