Part 2

25. NOTE: Apply a light film of lubricant on the front and rear pinion bearings.

Install the pinion bearings and special tools as shown.








26. NOTE: This step duplicates pinion bearing preload.

Thread the special tool onto the screw and tighten.
^ Tighten to 2.2 Nm (20 lb-in) rotational torque.





27. NOTE: The special tool must be offset to obtain an accurate reading.

Position the special tool.





28. Install the special tool.
^ Tighten to 105 Nm (77 lb-ft).





29. NOTE: Drive pinion bearing adjustment shims must be flat and clean.

NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in the final assembly of integral rear axle assemblies.

Use a drive pinion bearing adjustment shim as a gauge for shim selection.
^ After the correct shim thickness has been determined, remove the special tools.





30. Using the special tools, press the inner pinion bearing and pinion shim until they are firmly seated on the pinion.





31. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder.





32. Install a new outer pinion bearing and rear axle drive pinion shaft oil slinger.





33. CAUTION: Installation without the correct tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one.

CAUTION: Coat the lips of the rear axle drive pinion seal with grease.

Place the drive pinion oil seal on the special tool and drive the seal into place.





34. NOTE: Lubricate the pinion flange splines with rear axle lubricant.

Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing. Seat the drive pinion with a plastic hammer.





35. NOTE: Disregard the scribe marks if a new pinion flange is being installed.

Align the pinion flange with the drive pinion shaft.





36. With the drive pinion in the axle housing, install the pinion flange using the special tool.





37. Position the new pinion nut.





38. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new drive pinion collapsible spacer and pinion nut must be installed.

CAUTION: The pinion flange holding tool must be removed before preload readings can be taken.

Using the special tool, tighten the pinion nut.
^ Rotate the pinion occasionally to make sure the drive pinion bearings are seating correctly.
^ Install a Nm (lb-in) torque wrench on the pinion nut.
^ Rotating the pinion through several revolutions, take frequent drive pinion bearing torque preload readings until the preload reading is obtained.





39. With the pinion depth set and the pinion installed, place the differential case in the rear axle housing.

40. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.

Install a shim as shown on the left side.





41. NOTE: Apply pressure toward the left side to make sure the left bearing cup is seated.

Install the left bearing cap and loosely install the bearing cap bolts.





42. Install progressively larger shims on the right side until the largest shim selected can be installed by hand.





43. Install the right side bearing cap and tighten the bolts.
^ Tighten to 105 Nm (77 lb-ft).





44. Rotate the differential case to make sure it rotates freely.





Measuring backlash
45. Using the special tools, measure and note the differential ring gear backlash.
^ If backlash is within the specification, refer to Backlash within specification.
^ If a zero backlash condition occurs, refer to Zero backlash.
^ If backlash is not within the specification, refer to Backlash not within specification.









Zero backlash
46. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Measure the backlash.

Backlash not within specification
47. To increase or decrease backlash, remove the differential bearing caps and install a thicker shim and a thinner shim accordingly.
^ If backlash is not within the specification, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount.
48. Rotate the differential assembly several times to verify that the differential bearings seated correctly.





49. Using the special tools, recheck the backlash.
^ If backlash is within the specification, refer to Backlash within specification. If backlash is not within the specification, repeat Backlash not within specification in this procedure.





Backlash within specification
50. Remove the bolts and the differential bearing caps.
51. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown.





52. Install the differential bearing caps and bolts.
^ Tighten to 105 Nm (77 lb-ft).





53. Using the special tools, recheck the backlash.





54. Remove the axle assembly from the holding fixture and install the torque arm.
^ Tighten to 205 Nm (150 lb-ft).





55. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to make sure the silicone sealant has cured correctly.

Install the differential housing cover and tighten the differential housing cover bolts.
^ Tighten to 32 Nm (24 lb-ft).





56. Fill with axle lubricant.