Part 2

11. Place a new drive pinion collapsible spacer on the pinion stem.





12. Install the outer pinion bearing.





13. Install the slinger.





14. NOTE: Coat the lips of the pinion seal with front axle lubricant.

Place the pinion seal on the special tool.





15. Place the special tool and seal in the pinion seal bore and drive the seal into place.





16. Lightly lubricate the pinion gear splines with front axle lubricant.
17. Position the drive pinion in the housing.

18. CAUTION: Never install the drive pinion universal joint flange with a hammer or power tools.

NOTE: Disregard the scribe marks if installing a new flange.

Align the index marks and position the universal joint flange on the drive pinion.





19. Using the special tool, install the drive pinion universal joint flange.





20. Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut.

21. CAUTION: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut.

Install the special tool, and tighten the pinion nut.
^ Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with a Nm (inch-pound) torque wrench.








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





23. Install the ring gear.
1 Place the ring gear on the differential assembly.
2 Position 3 bolts to align the holes in the ring gear and the differential case.
3 Using a suitable press, position the ring gear.
4 Press the ring gear into place.





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





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. Position the differential case assembly.
1 Position the differential bearing cups on the differential bearings.
2 Lower the differential case assembly in place.





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





28. 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.





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 ft. lbs.).





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





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





41. CAUTION: Overspreading may damage the differential housing.

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

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





42. CAUTION: To avoid galling the case, insert shims with a light coating of grease before installing the differential assembly. If not carried out in this order, the aluminum housing can be damaged.

Place the differential bearing shims in the differential housing.





43. 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.





44. NOTE: Hand-tighten the differential bearing 47. Rotate the differential carrier to make sure it cap bolts prior to releasing the carrier spreader.

Install the differential bearing caps and the differential bearing cap bolts in their original locations and positions.





45. Loosen and remove the special tool.





46. Tighten the 4 differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).





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





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





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





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





51. Verify an acceptable pattern check.

52. 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 ft. lbs.).





53. Examine the axle shaft seal and bearing surface for damage. If necessary, polish the bearing surface with fine crocus cloth.





54. Install a new retainer circlip on each axle shaft.





55. Insert the axle shafts and engage them with the side gears.





56. Push in on the axle shafts until the retaining circlips expand in the side gears.





57. Remove the axle assembly from the Holding Fixture and place it on the bench.

58. 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.





59. Install the differential housing cover.





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





61. Install the front drive axle assembly.