Differential Carrier Cover and Seal Replacement - Right Side (RPO KNR)

Differential Carrier Cover and Seal Replacement - Right Side (RPO KNR)


Tools Required
* DT-47596 Bearing Cup Remover
* J 42170 Bearing and Race Installer
* J 45124 Removal Bridge
* J 46405 Output Shaft Seal Installer



Removal Procedure





1. Remove the right rear wheel drive shaft. Refer to Wheel Drive Shaft Replacement (Service and Repair) .
2. Remove the right rear muffler assembly. Refer to Exhaust Muffler Replacement - Right Side (Service and Repair) .
3. Drain the differential fluid. Refer to Lubricant Change (Removal and Replacement) .
4. Support the differential assembly.
5. Remove the right differential mount.
6. Remove the retaining bolts.
7. Remove the differential cover.
8. Remove and discard the axle seal (1, 4).




9. Install the DT-47596 (2) into the right cover. Tighten securely into the bearing cup.
10. Place the J 45124 (1) over the DT-47596 (2). Adjust the legs for the best fit. Install the supplied bolt, nut thrust and washer. Hold the bolt and tighten the nut to remove the bearing cup and shim.




11. Mark or tag the shims (1, 2) for assembly.





Important: Whenever service requires the replacement of the right side differential cover, the covers MUST be measured and the right shim pack adjusted to compensate for machining tolerances between the two components. Failure to perform this measurement procedure may result in improper differential bearing preload.


12. Use a vernier caliper (2) and a straight edge (1), in order to measure the NEW differential cover bore dimension. Record the measurement as value A.
13. Use a vernier caliper (2) and a straight edge (1), in order to measure the old differential cover bore dimension. Record the measurement as value B.
14. Subtract value B from value A. If the computation is a positive value, add shims equal to the value, to the existing shim pack. If the computations a negative value, subtract shims equal to the value, from the existing shim pack.



Installation Procedure





1. Install the selected shims (2) and the bearing race (1) to the new cover.




2. Press the shims and bearing race into the new cover using the J 42170 and a hydraulic press.




3. Clean the O-ring sealing surface on the differential cover and the differential housing.
4. Install a NEW O-ring (4) to the differential cover (3).
5. Install the differential cover.

Notice: Refer to Fastener Notice (Fastener Notice) .

6. Install the differential cover retaining bolts.

Tighten the retaining bolts to 28 N.m (20 lb ft).





7. Install the axle seal into the differential cover using J 46405 .
8. Fill the rear axle differential with the proper fluid and level. Refer to Lubricant Change (Removal and Replacement) .
9. Install the right rear muffler. Refer to Exhaust Muffler Replacement - Right Side (Service and Repair) .
10. Install the right rear wheel drive shaft. Refer to Wheel Drive Shaft Replacement (Service and Repair) .