Assemble

^ Tools Required
- J24385-01 Differential Case Spreader
- J 39705 Master Differential Bearings





1. Lubricate all of the parts with an axle lubricant.
2. Install new thrust washers to the side gears.

Important: Install the side gear thrust washer and the side gears to the same side that the side gears were on when the side gears were removed.

3. Install the side gears and the thrust washers to the differential case.
4. Install the pinion gears to the differential with the thrust washers.
4.1. Install the pinion gears to the side gears so that the holes in the pinion gears are 180 degrees apart.
4.2. Rotate the pinion gears into place. Verify that the pinion gears line up with the pinion shaft holes.
5. Rotate the pinion gears toward the differential opening in order to allow enough space for the pinion thrust washers to slide in.
6. Install the pinion shaft.
7. Align the roll pin holes in the differential case and the pinion shaft.
8. Install the roll pin.
8.1. Peen metal from the case over the lock pin in two places that are 180 degrees apart.
8.2. Ensure the mating surfaces of the differential case and the ring gear are clean and free of burrs.
9. Align the holes in the differential case and the holes in the ring gear. Press the ring gear onto the case.

Notice: Refer to Fastener Notice in Service Precautions.

Important: Tighten the ring gear bolt in stages in order to gradually pull the ring gear onto the differential case.

10. Install new ring gear bolts.
^ Tighten the ring gear bolts for 8.6 axle in sequence to 120 Nm (89 ft. lbs.)
^ Tighten the ring gear bolts for 9.5 axle in sequence to 139 Nm (103 ft. lbs.)
^ Tighten the ring gear bolts for 10.5 axle in sequence to 165 Nm (122 ft. lbs.)





11. Install the case side bearing J 39705 to the differential case.
^ Refer to Determining Total Shim Pack Size.
^ Put the outboard spacers in place, if outboard spacers are used.