Assembly

ASSEMBLY




1. Lubricate all differential components with hypoid gear lubricant.
2. Install differential side gears (2) and thrust washers to Fixtures 9631 (1) as shown in illustration.




3. Install differential pinion gears (1) and thrust washers into position across from each other.




4. Rotate pinion gears into place using Fixture 9631 and line up gear centers with pinion shaft bore.




5. Using a brass hammer, drive pinion shaft (3) into differential case (1), making sure to line up roll pin bores.
6. Using suitable punch (2), drive new roll pin into position.




7. Measure differential gear rotating torque as shown. Differential gear rotating torque should be 5-30 N. cm (44-266 in. lbs.) Rotating torque is adjusted using select side gear thrust washers. Refer to the following chart.

Available Side Gear Thrust Washer Thicknesses:

8. Remove differential case from Mounting Plate 9630 (2).




9. Install ring gear to case. Lightly tap ring gear into position to facilitate starting of bolts.
10. Install new ring gear-to-case bolts and torque to 85 Nm (63 ft. lbs.).




11. Using Installer 9523 (2) and Handle C-4171 (1), press new differential side bearings (3) onto differential case.