Part 2

Axle






















Front Axle Assembly - Disassembled View










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 2 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 2 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 Dial Indicator Gauge with Holding Fixture.





34. Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, 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 Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier Spreader.





42. NOTICE: 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 Dial Indicator Gauge to zero.

2. Tighten the screw until spreading the differential housing to the specifications.

3. Remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.






43. NOTICE: 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 2 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 Differential Carrier Spreader.
Install the 2 differential bearing caps and 4 bolts in their original location.






46. Loosen and remove the Differential Carrier Spreader.





47. Install the Dial Indicator Gauge with Holding Fixture at the 12 o'clock position.





48. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the ring gear backlash.





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

50. Verify an acceptable pattern check. For additional information, refer to Diagnosis and Testing. Testing and Inspection

51. Assemble the axle housing tube.
- Align the bolt holes and position the axle tube.

- Position the axle identification tag.

- Install the 4 bolts.
- Tighten to 73 Nm (54 lb-ft).







52. Install a new stub shaft seal. For additional information, refer to Stub Shaft Pilot Bearing and Seal Stub Shaft Pilot Bearing and Seal.

53. Install a new circlip on the intermediate shaft end.





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. NOTE: Remove all of the silicone gasket and make sure the surfaces are free of oil before applying the new silicone gasket.
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 one hour before filling with lubricant to make sure the silicone sealant has correctly cured.
Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface as shown in the illustration.
- Use silicone gasket and sealant.






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






58. Install the axle assembly. For additional information, refer to Axle Assembly Axle Assembly.

59. Remove the fill plug and fill the axle assembly with the specified type and amount of lubricant.
- Tighten the fill plug to 25 Nm (18 lb-ft).