Differential Carrier

REMOVAL & INSTALLATION

1983–95 Pick-Ups and 1983–91 Monteros

1. Elevate and safely support the vehicle on stands.
2. Remove the rear wheels.
3. Drain the differential assembly.
4. Remove the brake drum and disconnect the parking brake cable at the brake assembly. It may be necessary to remove or loosen some of the cable retaining brackets.
5. Disconnect the brake lines running to the wheel cylinder.
6. Remove the rear axle retaining nuts.
7. Remove the axles. A slide hammer will be needed for the axles' removal. Note that the axles need only be pulled free of the differential (about 3 in./76mm) not completely removed.
8. Matchmark and disconnect the driveshaft flange at the differential case.
9. Support the differential carrier with a floor jack.
10. Remove the attaching nuts around the circumference of the axle housing. Work the carrier forward and out of the housing. Lower the jack with the unit when it is clear of the axle.

    NOTE: The carrier may be stuck in place. Leave one nut in place but loosened on the upper stud. Use a piece of square lumber under the carrier case to push or tap upward. This will break the seal around the casing.

11. Make certain that the carrier is balanced on the jack. Elevate the jack to lift the carrier off the insulator studs. As soon as the unit clears the studs, move the jack forward and lower it to remove the carrier.

    Fig. 1: Rear differential carrier removal and installation — all trucks except for 1992–95 Monteros

    Fig. 2: Use a piece of wood to tap the carrier loose — make sure to leave one nut on the top stud to keep the carrier form falling

    Fig. 3: Apply the sealant to the differential carrier using either one of the two styles shown in the illustration

    To install:

12. Install 3M® ART Part No. 8663, 8661 or the equivalent to the differential carrier mounting surface of the axle housing.
13. Reinstall the unit by mounting it in position and securing the retaining bolts and nuts. The ring of nuts should be tightened evenly and alternately to 20 ft. lbs. (27 Nm).
14. Install the front to rear driveshaft and connect it to the differential. The flange joint bolts should be tightened to 41 ft. lbs. (55 Nm).
15. Install the axles following procedures outlined earlier in this section. The axle retaining bolts should be tightened to 41 ft. lbs. (55 Nm).
16. Connect the brake lines to the wheel cylinder, connect the parking brake cable and install the drum. Don't forget to secure the parking brake cable brackets if any were loosened or removed.
17. Bleed the brake system by following the procedures outlined in Section 9.
18. Install the differential drain bolt to 47 ft. lbs. (65 Nm). Fill the differential with the correct amount of lubricant.
19. Install the wheels.
20. Lower the vehicle to the ground.
21. Test drive the vehicle and check for leaks.

1992–95 Montero

1. Remove the rear brake calliper mounting bolts, then pull the calliper off of the read disc. Hang the calliper from the vehicle frame using strong wire or cord. Do not disconnect the brake lines if it can be helped.
2. Pull the rear brake disc off of the axle.
3. Disconnect the rear parking brake cable from the brake assembly under where the brake disc was located.
4. Remove the rear axle retaining nuts and pull the rear axles out only 3 in. (70mm). Do not remove the axles entirely.
5. Matchmark and remove the rear driveshaft from the rear differential housing. It may not be necessary to remove the driveshaft from the transmission if it is not in the way.
6. Remove the rear differential lock position harness connector.
7. Disconnect the differential front hose, if so equipped.
8. Remove the attaching nuts around the circumference of the axle housing. Work the carrier forward and out of the housing. Lower the jack with the unit when it is clear of the axle.

   NOTE: The carrier may be stuck in place. Leave one nut in place but loosened on the upper stud. Use a piece of square lumber under the carrier case to push or tap upward. This will break the seal around the casing.

9. Make certain that the carrier is balanced on the jack. Elevate the jack to lift the carrier off the insulator studs. As soon as the unit clears the studs, move the jack forward and lower it to remove the carrier.

   Fig. 4: Rear differential carrier removal and installation — 1992–95 Monteros with rear disc brakes

   To install:

10. Install 3M® ART Part No. 8663, 8661 or the equivalent to the differential carrier mounting surface of the axle housing.
11. Reinstall the unit by mounting it in position and securing the retaining bolts and nuts. The ring of nuts should be tightened evenly and alternately to 35 ft. lbs. (47 Nm).
12. Connect the rear differential lock position harness and the differential front hose.
13. Install the front to rear driveshaft and connect it to the differential. The flange joint bolts should be tightened to 41 ft. lbs. (55 Nm) for the 3.0L engines and to 76 ft. lbs. (103 Nm) for the 3.5L engines.
14. Install the axles following procedures outlined earlier in this section. The axle retaining bolts should be tightened to 41 ft. lbs. (55 Nm).
15. Connect the parking brake cable and install the rear brake disc. Don't forget to secure the parking brake cable brackets if any were loosened or removed.
16. Install the brake calliper to the disc and tighten the mounting bolts.
17. Install the differential drain bolt to 47 ft. lbs. (65 Nm). Fill the differential with the correct amount of lubricant.
18. Install the wheels.
19. Lower the vehicle to the ground.
20. Test drive the vehicle and check for leaks.