Differential Case Assembly

INSTALLATION PROCEDURE

- Tools Required
- J 8092 Driver Handle
- J 8107-4 Differential Side Bearing Puller Pilot
- J25299 Differential Side Bearing Installer





1. Lubricate all the parts with axle lubricant.
2. Install the thrust washers to the side gears.
3. Install the side gears to the differential case on the same side in which the parts were removed.
4. Place one pinion gear on the side gear. Rotate the gear until the pinion is exactly opposite the differential opening.
Install the pinion gears to the differential without the thrust washers.
5. Rotate the pinion gears into place. Verify the gears line up with the pinion shaft holes.
6. Install the pinion shaft.
7. Install the pinion shaft lock bolt finger tight.
8. Inspect the mating surfaces of the differential case for cleanliness, and that the surfaces are free of burrs.





9. Install the ring gear to the differential case.
10. Install two threaded studs into the ring gear on opposite sides.
11. Place the ring gear on the case. Align the studs with the holes in the case.
12. Install the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.
- Tighten the ring gear bolts in sequence to 120 Nm (90 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.





13. Install the differential side bearings, using J 25299, J 8092, and J 8107-4.
- In order to protect the differential case, place J 8107-4 in the case on the side opposite the bearing installation.
- Drive the bearing onto the case using J 25299 and J 8092.

14. Install the differential case to the axle housing.