Part 2

22. Use a fine flat file to remove any burrs or nicks from the ring gear mounting surface.





23. Install the ring gear.
1 Position 3 bolts to align the holes in the ring gear and the differential case.
2 Using a suitable press, install the ring gear.





24. Install the remaining bolts.
^ Tighten to 105 Nm (77 lb-ft).





25. CAUTION: Press against the bearing inner core only.

Using a suitable press and the special tool, install the differential bearings.
1 Position the appropriate differential bearing (RH or LH).
2 Using a suitable press and the special tool, install the differential bearing.
^ Repeat the procedure for the other differential bearing.





26. Install the differential carrier.
1 Position the differential bearing cups on the differential bearings.
2 Lower the differential carrier in place.





27. Install a differential bearing shim of the thickness shown on the LH side of the differential bearing.





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

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





29. Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.





30. Install the right bearing cap and bolts.
31. Tighten the 4 differential bearing cap bolts.
^ Tighten to 105 Nm (77 lb-ft).





32. Rotate the differential carrier to make sure it turns freely.





33. Install the special tool.





34. Measure the ring gear backlash at 4 places to obtain a consistent reading.





35. NOTE: If the backlash is not within the specifications, correct it by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.

To increase the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.





36. To decrease the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.





37. Select the appropriate shim by the thickness or the stripe color.





Differential Shim Size Chart





38. Remove the 4 differential bearing cap bolts.
^ Remove the differential carrier.





39. Measure the thickness of the selected right and left bearing shims.
40. To establish differential bearing preload, increase both the left and right differential bearing shim thickness by 0.203 mm (0.008 in).
41. Install the special tools.





42. CAUTION: Overspreading may damage the differential housing.

NOTE: Tighten and loosen the differential carrier spreader adapters to normalize the housing adapters prior to taking the final dial indicator reading.

Spread the differential housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the screw until spreading the differential housing to the specifications.
3 Remove the special tools.





43. CAUTION: To avoid galling the case, insert the shims with a light coating of grease before installing the differential carrier.

Place the differential bearing shims in the differential housing.





44. Install the differential carrier.
1 Position the differential bearing cups on the differential bearings.
2 Lower the differential carrier in place between the differential bearing shims.





45. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the special tool.

Install the differential bearing caps and bolts in their original location.





46. Loosen and remove the special tool.





47. Install the special tool at the 12 o'clock position.





48. Using the special tools, recheck the ring gear backlash.





49. Apply marking compound and rotate the differential assembly 5 complete revolutions.





50. Verify an acceptable pattern check.

51. CAUTION: Remove all of the old liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber.

CAUTION: Install the axle housing tube within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has cured.

CAUTION: Do not allow any silicone rubber to squeeze inside during assembly.

Assemble the axle housing tube.
^ Align the bolt holes and position the axle tube.
^ Position the axle identification tag.
^ Install the bolts.
Tighten to 73 Nm (54 lb-ft).





52. Install a new O-ring and new circlips on the intermediate shaft ends.





53. Install a new stub shaft seal.
54. Insert the intermediate shaft and engage the circlip with the side gears.
55. Remove the axle assembly from the Holding Fixture and place it on the bench.

56. CAUTION: Remove all of the old liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber

CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has cured.

Fill the sealing groove on the differential housing cover with silicone gasket and sealant.





57. Install the differential housing cover and the 10 cover bolts.
^ Tighten to 32 Nm (24 lb-ft).





58. Fill the differential carrier housing, and install the fill plug.
^ Use rear axle lubricant.





59. Install the front drive axle assembly.