Differential Case Assembly

^ Tools Required:
- J 25299 Differential Side Bearing Installer
- J 8092 Driver Handle
- J 8107-2 Differential Side Bearing Remover Plug

INSTALL OR CONNECT
1. Lubricate all parts with axle lubricant.
2. Thrust washers to the side gears.
3. Side gears to the differential case.
- Install the side gears on the same side as removed.
4. Pinion gears to the differential without the thrust washers.
A. Place one pinion gear on the side gear and rotate the gear until the pinion is exactly opposite from the differential opening.
B. Place the second pinion gear on the side gear so the pinion gear holes line up.
C. Rotate the pinion gears into place, and verify the pinion gears line up with the pinion shaft holes.
5. Pinion thrust washers.
- Rotate the pinion gears toward the differential opening enough to slide in the pinion thrust washers.
6. Pinion shaft.
7. Pinion shaft lock bolt.
- Use a new pinion shaft lock bolt.
- Check that the mating surfaces of the differential case and the ring gear are clean and burr free.





8. Ring gear to the differential case.
A. Install two threaded studs into the ring gear on opposite sides.
B. Place the ring gear on the case and align the studs with the holes in the case.
9. Ring gear bolts.
- Tighten:
^ The ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.
^ The ring gear bolts in sequence to 120 Nm (9O ft. lbs.).





10. Differential side bearings using J 25299, J 8092, and J 8107-2.
- Place J 8107-2 in the differential case on the side opposite of bearing installation to protect the differential case.
- Drive the bearing onto the case using J 25299 and J 8092.
11. Differential case to the axle housing. Refer to SIDE BEARING PRELOAD ADJUSTMENT.