Assembling the Differential Into the Axle Housing
- Tools Required:- J 8092 Driver Handle
- J 23690 Differential Side Bearing Installer
- J 24385-01 Differential Carrier Spreader
- D 136/D 346 Master Differential Bearings
- D 128 Dial Indicator Set or Equivalent
NOTICE:
- If your axle assembly has selective outboard spacers and one 0.76 mm (0.030 inch) shim (each side) between the differential case and bearing cone, make your measurements with the outboard spacers removed, but with the 0.76 mm (0.030 inch) shim assembled on the differential case trunnion placed between the case and the master differential bearing. The selective outboard spacers are available in sizes (thickness) from 5.18 mm (0.2040 inch) to 6.10 mm (0.2400 inch), in 0.08 mm (0.003 inch) increments. The dial indicator should have the capability of making measurements up to 12.7 mm (0.500 inch).
- If your axle assembly has outboard spacers, but controls the preload and backlash by using selective shims (each side) between the differential case and bearing cone, make the measurements with the outboard spacers installed in the housing, but do not place any shims on the differential case hubs between the case and master differential bearings. The selective shims placed between the bearing cone and differential case are available in 0.08, 0.13, 0.25, 0.76 mm (0.003, 0.005, 0.O10, 0.030 inch). The dial indicator should have the capability of making measurements up to 3.81 mm (0.150 inch).
1. Force the ring gear to mesh with the pinion. Rock the ring gear to allow the teeth of the gears to mesh.
2. Assemble the differential with master bearings installed to the axle. The pinion must be installed.
3. Mount a dial indicator with a magnetic base on the ring gear bolt side of the housing.
4. Place the indicator tip on the chalk mark made earlier.
5. With the force still applied to the differential case, set the dial indicator to zero.
6. Force the differential case away from the pinion gear to obtain an indicator reading. Repeat this action until a consistent reading is obtained. Record the reading.
7. Remove the indicator and the differential case from the axle housing.
8. Remove the master bearings from the differential case.
9. Using the total shim pack size determined earlier, (refer to DETERMINING TOTAL SHIM PACK SIZE) subtract the reading found in Step 6 from the total reading. The reading found in Step 6 will be the shim size on the ring gear side. The remaining portion of the shim pack will be used on the side opposite the ring gear. Add an additional 0.25 mm (0.010 inch) of shims to the side opposite the ring gear to preload the bearings.
10. Place the proper shims on the differential side of bearing hub (ring gear side) and drive the differential bearing onto the hub using J 8092 and J 23690.
Important: If the axle assembly uses the outboard selective spacers, place the 0.76 mm (0.030 inch) shim on the hub that was used along with the master bearings to make the measurement. Then select the appropriate outboard selective spacer and assemble into housing.
11. Place the proper shims on the differential side bearing hub (opposite the ring gear) and drive the differential bearing onto the hub using J 8092 and J 23690.
Important: If the axle assembly uses the outboard selective spacers, place the 0.76 mm (0.030 inch) shim on the hub that was used along with the master bearings to make the measurement. Then select the appropriate outboard selective spacer and assemble into housing.
12. Assemble J 24385-01 to the axle.
13. Assemble the dial indicator. Preset the gage at least 0.05 mm (0.020 inch), then rotate the indicator housing to zero the dial.
NOTICE: Do not spread the axle housing more than 0.38 mm (0.015 inch). Over-spreading can damage or distort the housing.
14. Spread the housing while examining the dial indicator.
15. Remove the dial indicator.
16. Place the bearing cups onto the bearings.
17. Install the differential assembly into the carrier.
- Use a soft-faced hammer to seat the differential assembly in the axle housing.
18. Remove the spreader.
19. Install the bearing caps in their original positions.
20. Install the bearing cap bolts.
- Tighten bearing cap bolts to 115 Nm (85 ft. lbs.).