Assembly

PINION & RING GEAR BACKLASH

1. Assemble ring gear to differential case. Using new bolts torque alternately and evenly to 45---60 ft. lbs on model 44 and 50 axles or 50---60 ft. lbs. on model 28 axles. On model 60 monobeam axle, note specifications given in step 14.
2. Place differential case into position in the carrier (master bearing should still be installed).
3. Force differential case away from the drive pinion gear, until it is completely seated against the cross bore face of the carrier. Position a dial indicator so the indicator tip rests on a differential case bolt. Zero dial indicator. Force ring gear against pinion gear. Rock ring gear slightly to ensure dial indicator returns to zero. Repeat this procedure until the dial indicator reading is the same. This reading reveals the amount of shims necessary between differential case and differential bearing on ring gear side. Remove differential case from the carrier and master bearings from case. As determined previously, place required amount of shims on the ring gear hub of the differential case.
4. Install bearing cone onto hub of the ring gear side of the differential case. Drive bearing onto hub.
5. To determine the correct amount of shims to be placed on the hub of the drive pinion side of the differential case, subtract reading obtained previously from the differential total case endplay. When this amount is determined, add .010 inch on model 44 and 50 axles or .015 inch on model 60 axle or .003 inch on model 28 axles to this amount. This is the required amount of shims to be placed on the hub of the drive pinion side of the differential case.
6. Place required amount of shims onto hub of the drive pinion side of the differential case. Install bearing cone onto hub of the drive pinion side of the differential case. Place suitable step plate tool onto ring gear side bearing to protect the bearing. Drive bearing onto hub of the drive pinion side of differential case. Place required amount of shims on the hub of drive pinion side of the differential case.
7. Install bearing cone onto hub of the drive pinion side of the differential case. Place step plate tool onto ring gear side bearing to protect bearing. Drive bearing onto hub of the drive pinion side of the differential case. Install bearing cone onto pinion side of differential case. Place pinion bearing cone replacer tool onto ring gear bearing to prevent damage.
8. Install differential bearing cups onto bearing cones. With spreader and dial indicator installed on case, spread carrier housing but do not exceed amount(s) specified previously. Install differential case into carrier. If necessary use a suitable mallet to seat the differential case into the carrier. With partial and non-hunting/partial ring gear and pinion sets, align marks on the ring gear and drive pinion. Ensure not to nick the teeth of the ring gear or pinion. Remove spreader and dial indicator from case.
9. Install bearing caps and bolts. Ensure letters or numbers stamped on the caps correspond in both position and direction with the letters or numbers stamped into the carrier assembly.
10. Install dial indicator onto case. Check ring gear and pinion backlash at three equally spaced points on ring gear. Backlash tolerance is .005---.009 inch on except model 28 axles or .005---.008 inch on model 28 axles and cannot vary by more than .003 inch between the three points. If backlash is high, the ring gear must be moved closer to the pinion, by moving shims to the ring gear side from the opposite side. If backlash is low, the ring gear must be moved away from the pinion by moving shims from the ring gear side to the opposite side.
11. Apply a suitable bead of sealant onto mating surfaces of the carrier mounting face support arm. Allow one hour curing time after axle carrier is assembled to the axle arm before installing lubricant and operating vehicle.
12. Mount differential assembly to the lefthand axle arm, using 2 guide pins and being careful not to smear gasket sealant.
13. On except model 60 monobeam axles, install and torque bolts to 30---40 ft. lbs on except model 28 axles or 40---50 ft. lbs on model 28 axles. Install support arm tab bolts to side of carrier and torque to 82---100 ft. lbs on except model 28 axle or 75---95 ft. lbs (carrier shear bolt) on model 28 axle.
14. On model 60 monobeam type axle, torque the following bolts to specification as follows:
a. Torque pinion shaft nut to 240---300 ft. lbs.
b. Torque differential bearing cap screws to 80---90 ft. lbs.
c. Torque ring gear attaching bolts to 100---120 ft. lbs.
d. Torque cover to housing bolts to 30---40 ft. lbs.
e. Torque tracking bar nut and bolt to 163---203 ft. lbs.