Assembly

Fig. 12 Measuring axle shaft:

1. Mount one axle shaft in a vise with the splined end facing upward. Do not allow end of shaft to extend more than 3 inches above top of vise.
2. Assemble clutch packs into side gear plate in same position as removed.

Fig 20 Clutch Pack Installation:

3. Align plate ears and install assembled pack into flange half. Ensure clutch plate lugs enter slots in case. Also ensure clutch pack bottoms out on case.
4. Install pinion mate shafts and pinion mate gears. Ensure shafts are correctly installed according to alignment marks.
5. Lubricate and install other side gear and clutch pack as done above.
6. Correctly align and assemble button half to flange half, then install case body screw finger tight.
7. Place case assembly onto axle shaft fixture. Install another axle shaft into opposite side gear. Torque case bolts alternately and evenly to 65-70 ft. lbs. Both axle shafts must be inserted all the way on each side to align both splines. If bolt heads have 7 radial lines stamped on head, torque these to 90-100 ft. lbs.
8. Remove differential assembly from axle shaft. Ensure pinion mate cross shaft is tight on ramp, clearance should not exceed 0.010 inch, being equal at all four shaft ends.