Assembly

ASSEMBLY
1. Install side gear thrust washer (Figure 1).




Figure 1 Side Gear Thrust Washer


1 - SIDE GEAR THRUST WASHER

2. Install differential side gear (Figure 2).




Figure 2 Differential Side Gear


1 - DIFFERENTIAL SIDE GEAR

3. Install four (4) pinion gears and thrust washers (Figure 3).




Figure 3 Pinion Gear and Thrust Washer






4. Install pinion shaft retaining ring (Figure 4).




Figure 4 Pinion Shaft Retaining Ring


1 - RETAINING RING

5. Install two (2) short pinion shafts (Figure 5).




Figure 5 Short Pinion Shaft (2)


1 - PINION SHAFT (SHORT (2))

6. Install one (1) long pinion shaft (Figure 6).




Figure 6 Long Pinion Shaft


1 - PINION SHAFT (LONG)

7. Install differential side gear.
8. Install side gear thrust washer (Figure 7).




Figure 7 Side Gear Thrust Washer






9. Install differential support plate. Align support plate to differential case with alignment pins 8470 (Figure 8).




Figure 8 Align Differential Support to Case






10. Install thrust buttons 8491 to both bearing journals and press halves together using an arbor press (Figure 9).




Figure 9 Installing Differential Support






11. Install ring gear into position, start three ring gear-to-differential case bolts by hand (120� apart), and install alignment pins 8470 (Figure 10).




Figure 10 Ring Gear Alignment/Installation






12. Torque three ring gear bolts to draw ring gear into position. Remove alignment pins, install remaining ring gear-to-differential case bolts and torque to 95 Nm (70 ft. lbs.) (Figure 11).




Figure 11 Ring Gear-to-Differential Case Bolts






13. Install tapered roller bearings using installer 8473 and an arbor press (Figure 12). Insert button 8491 on opposite journal to protect journal and/or bearing during press operation. Repeat the same operation on opposite side.




Figure 12 Differential Side Bearing Installation






14. Measure and verify differential side gear end play.