Assembly

Clutch Plate:

1. Prelubricate each disc and plate with Additive Friction Modifier C8AZ-19B546-A (EST-M2C118-A), or equivalent friction modifier lubricant.

Clutch Pack Assembly:

2. Prelubricate the thrust face of the side gear. Assemble the plates and discs to the side gear splines in exactly the same sequence in which they were removed. Assemble the retainer clips to the ears of the plates. Make sure both clips are completely assembled and seated onto the ears of the plates.

Clutch Pack Installation:

3. Install Differential Holding Tool, D83T-4205-A in a suitable vise. Place differential case on holding tool with ring gear side facing up. Insert the clutch pack and side gear assemblies into the differential case. Make sure that the clutch packs stay assembled to the side gear splines, and that the retainer clips are completely seated in the pockets of the differential case. Hold the upper clutch pack and side gear assembly in place to prevent it from falling out of the differential case.

Side Gear Installation:

4. Position Step Plate, D83T-4205-C2, in the bottom side gear bore. Apply a small amount of grease to the step plate bore. Position nut, part of D83T4205-C, in the top side gear bore and hold it in place. Install the Hex Screw Tool, part of D83T-4205-C, and tighten it two turns after it contacts the bottom step plate. Insert the Dowel Bar or equivalent, part of D83T-4205-C, in nut bore to keep the nut from turning as the hex screw is tightened.

Pinion Gear Installation:

5. Position the pinion gears in the window of the differential case so that they mesh with the side gear teeth. Hold the pinion gears in place. Make sure that the pinion gears are 18O° apart so they will correctly align with the pinion shaft bore.

Walking Pinion Gears Into Place:

6. Insert the Rotating Tool, T86T-4205-A, into the pinion shaft bore and turn the differential case. This will cause the pinion gears to engage the side gears and "walk" into the differential case. Rotate the differential case until the pinion mating shaft holes are lined up exactly with the holes in the pinion gears.

NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the pinions and side gears to rotate.

Thrust Washer Installation:

7. Prelubricate both sides of the pinion thrust washers with Hypoid Gear Lubricant, EOAZ-19580-A (ESP-M2C154-A) or equivalent. Apply torque to the forcing screw to allow clearance to insert the thrust washers. Insert the pinion gear thrust washers between the pinion gears and the differential case with the concave side facing in.

Thrust Washer Alignment:

8. Be sure to align the thrust washer holes with the bore in the differential case PRIOR to installing differential pinion shaft.

Pinion Shaft Installation:

9. Loosen the forcing screw and remove the step plate and nut from the side gear bores. Install the pinion shaft in the differential case. Install the pinion shaft lock bolt and tighten to 20-40 Nm (15-30 ft-lb).

10. If removed, install the ring gear on the differential case and tighten the attaching bolts to specifications. For detailed procedures and specifications, refer to Integral Carrier Axle-10.25 Inch Ring Gear.