Differential Carrier Cover and Seal Replacement - Right Side

Differential Carrier Cover and Seal Replacement - Right Side

Special Tools

* 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 rear wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement Service and Repair.

2. Remove the right rear muffler assembly. Refer to Exhaust Muffler Replacement - Right Side Exhaust Muffler Replacement - Right Side.

3. Drain the differential fluid. Refer to Differential Oil Replacement 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 - remover (2) into the right cover. Tighten securely into the bearing cup.

10. Place the J-45124 - bridge (1) over the DT-47596 - remover (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.





Note: 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. Using the vernier caliper (2) and a straight edge (1), measure the NEW differential cover bore dimension. Record the measurement as value A.

13. Using the vernier caliper (2) and a straight edge (1), 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. Using the J-42170 - installer and a hydraulic press, install the shims and bearing race into the new cover.




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.

Caution: Refer to Fastener Caution Fastener Caution.

6. Install the differential cover retaining bolts and tighten to 28 Nm (20 lb ft).




7. Using the J-46405 - installer, install the axle seal.

8. Fill the rear axle differential with the proper fluid and level. Refer to Differential Oil Replacement Removal and Replacement.

9. Install the right rear muffler. Refer to Exhaust Muffler Replacement - Right Side Exhaust Muffler Replacement - Right Side.

10. Install the wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement Service and Repair.