Differential Case Assembly - M210 Front Axle: Notes

REMOVAL 

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1. Remove the differential cover.
2. Remove the left tie rod end from the knuckle and secure out of the way. Refer to END, TIE ROD, REMOVAL AND INSTALLATION .
3. Remove the track bar. Refer to TRACK BAR, FRONT, REMOVAL AND INSTALLATION .
4. Remove the axle shafts. Refer to REMOVAL AND INSTALLATION .

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   1 - Differential Cap Bolts

   2 - Reference Letters

   3 - Axle Locker Coil Anti-rotation Bracket

   NOTE:

   Note the reference letters stamped on the bearing caps and differential housing machined sealing surface.

5. If reference letters are not clearly visible, mark the bearing caps and differential housing so the caps can be reinstalled in their original positions.
6. Loosen the differential bearing cap bolts. Notice the orientation of the axle locker actuator bracket when removing the bearing caps.

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   1 - Hold Down Clamps

   2 - Spreader

7. Position the spreader (special tool #W-129-B, Spreader, Differential) with the adapter kit (special tool #6987B, Adapter Kit, Axle Spreader) on the differential locating holes. Install the hold-down clamps and tighten the turnbuckle finger-tight.

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   1 - Spreader

   2 - Dial Indicator And Mounting

   3 - 90° Dial Indicator Tip

8. Install a pin (special tool #C-3288-B, Set, Alignment Pins) at the left side of the differential housing. Attach the dial indicator with the SP-1917 or equivalent 90° dial indicator tip (special tool #C-3339A, Set, Dial Indicator) to the pin. Load the SP-1917 or equivalent 90° dial indicator tip against the opposite side of the housing and zero the dial indicator.
9. Spread the differential housing while measuring the distance with the dial indicator.
   CAUTION:

   Never spread housing over 0.50 mm (0.020 in). Failure to follow these instructions will damage the housing.

10. Remove the dial indicator.
11. Holding the differential case in position, remove the differential bearing caps.

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    1 - Pry Bar

    2 - Differential Case

12. Remove the differential case from the differential housing using a small pry bar or similar. Tag the differential bearing cups and shim locations.

CLEANING: 

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

INSTALLATION 

During installation, torque the fasteners to the specifications in the torque table(s) below.

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1. Install the differential case into the differential housing with bearing cups and preload shims. Tap the differential case to ensure the bearings cups are fully seated in the differential housing.

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   1 - Differential Cap Bolts

   2 - Reference Letters

   3 - Axle Locker Coil Anti-rotation Bracket

2. Install the bearing caps with reference marks in their original locations. Install the axle locker actuator bracket on the locker side of the differential. Center the pin from the axle locker actuator in the slot in the axle locker actuator bracket.
3. Loosely install the differential bearing cap bolts.
4. Remove the differential housing spreader.
5. Tighten the bearing cap bolts to the proper torque specification.
6. Install the axle shafts. Refer to REMOVAL AND INSTALLATION .
7. Install the track bar. Refer to TRACK BAR, FRONT, REMOVAL AND INSTALLATION .
8. Install the left tie rod end. Refer to END, TIE ROD, REMOVAL AND INSTALLATION .

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   1 - Differential Cover

9. Install the differential cover.
10. Remove the fill plug and fill the differential with the proper fluid. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .

TORQUE SPECIFICATIONS