Front Axle - 216FBI: Differential-TRU-LOK: Removal: Differential-TRU-LOK

Fig 1: Differential Cover

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1. Remove differential fill plug (2).
2. Remove differential cover (1) and drain fluid.
3. Remove axle shafts.
   Fig 2: Tru-Lok Harness

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4. Remove Tru-Lok harness from the coil connector (1) and indicator switch (2).
5. Remove Tru-Lok coil connector (1) bolt.
   Fig 3: Coil Harness

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6. Remove Tru-Lok coil connector (1) from the axle housing and remove coil harness (2) from the connector (1).
   Fig 4: Bearing Caps

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7. Loosen differential bearing cap (1) bolts.
   Fig 5: Spread Axle Housing

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8. Position Spreader W-129-B (2) with Adapter Kit 6987B on differential locating holes. Install hold-down clamps and tighten the turnbuckle finger-tight.
9. Install a Pin C-3288-B (1) at the left side of the differential housing. Attach Dial Indicator C-3339A to pin. Load indicator plunger against the opposite side of the housing and zero the indicator.
10. Spread housing while measuring the distance with the dial indicator (1).
    CAUTION: Never spread housing over 0.50 mm (0.020 in). Failure to follow these instructions will damage the housing.
    Fig 6: Coil Bracket

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11. Remove dial indicator.
12. Holding differential case in position, remove differential bearing cap bolts.
13. Remove coil anti-rotation bracket (1) from the bearing cap (2), then remove both bearing caps.
14. Remove differential case from housing and tag differential bearing cups and shims location.
15. Remove spreader from housing.
    Fig 7: Indicator Switch

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16. Remove Tru-Lok indictor switch (1) from differential housing (2).
17. Clean the housing cavity with flushing oil, light engine oil or lint free cloth.

NOTE: Do not use water, steam, kerosene or gasoline for cleaning.