Assemble

Differential Case Assembly Assemble

^ Tools Required
- J 8092 Universal Driver Handle - 3/4 in - 10
- J 22761 Differential Side Bearing Installer
- J 22888-D Side Bearing Remover Kit
- J 29710 Differential Side Bearing Installer
- J 36597 Side Bearing Puller Pilot - 9.25 in Axle





1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid.
2. Install the differential side gear thrust washers to the differential side gears.
3. Install the differential side gears and thrust washers into the differential case.
If the same differential side gears and the thrust washers are being used, install the side gears and the thrust washers to their original locations.
4. For the 8.25 inch axle, install the differential pinion gears and thrust washers by performing the following steps:
4.1. Position one pinion gear between the differential side gears.
4.2. Position the second pinion gear between the differential side gear directly opposite of the first gear.
4.3. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case.
4.4. Install the thrust washers.
Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers.
5. For the 9.25 inch axle, install the differential pinion gears and thrust washers by performing the following steps:
5.1. Install one of the pinion gears between the differential side gears.
5.2. Install the second pinion gear between the differential side gears directly opposite of the first gear.
5.3. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case.
5.4. Install the pinion gear thrust washers using a hammer and a brass drift.
5.5. Install the differential side gear spacers.
6. Install the pinion gear shaft.
7. For the 8.25 inch axle, install the new pinion gear shaft lock pin using a hammer and a brass drift.

Notice: Refer to Fastener Notice in Service Precautions.

8. For the 9.25 inch axle, install the pinion shaft lock bolt.
^ Tighten the pinion shaft lock bolt to 34 Nm (25 lb ft).





Important: The mating surface of ring gear and the differential case must be clean and free of burrs before installing the ring gear.

9. Install the ring gear onto the differential case.
10. Install the new ring gear bolts.
Hand start each bolt to ensure the ring gear is properly installed to the differential case.
11. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.
^ For the 8.25 inch axle, tighten the ring gear bolts in sequence to 120 Nm (88 lb ft).
^ For the 9.25 inch axle, tighten the ring gear bolts in sequence to 138 Nm (102 lb ft).





12. Install the differential side bearings by performing the following steps:
12.1. In order to protect the differential case, install the J 8107-2, B.25 inch axle, or the J 36597, 9.25 inch axle in the case on the side opposite the bearing installation.
12.2. Install the J 22761, 8.25 inch axle, or the J29710, 9.25 inch axle (2) and the J 8092 (1) onto the differential case bearing as shown.
12.3. Drive the differential case bearing onto the case using the J22761 or the J29710 and the J 8092.