Front Differential Case Assemble (9.25 Inch HD Axle)

Front Differential Case Assemble (9.25 Inch HD Axle)

Special Tools
* J 8092 - Universal Driver Handle - 3/4 in - 10
* J 36603 - Installer

1. Lubricate the pinion and side gears using axle lubricant. Use the correct fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers Mechanical Specifications.





Note: If the same differential side gears and the thrust washers are being used, install the gears and the washers to the original locations.

2. Install the thrust washers (1, 4) and the differential side gears (2, 3) into the differential case.




3. Position both pinion gears (2) between the differential side gears directly opposite of each other.
4. Rotate the differential side gears until the pinion gears (3) are aligned with the pinion shaft opening.
5. Install the thrust washers (1) in between the pinion gear and differential case.




6. Install the pinion gear shaft (1).

Caution: Refer to Fastener Caution Fastener Caution.

7. Install the differential pinion gear shaft lock bolt (2) and tighten to 53 Nm (39 lb ft).





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

8. Install the differential ring gear (2) on the differential case (1).





Note:
* The differential ring gear bolts are left-hand threads.
* DO NOT use air tools to tighten the differential ring gear bolts. Hand start each bolt to avoid cross threading the differential ring gear bolts.

9. Hand start the differential each of the 12 NEW differential ring gear bolts (1).
10. Using hand tools, tighten the differential ring gear bolts alternately and in stages until the differential ring gear is seated against the differential case.
11. Tighten the ring gear bolts in sequence to 138 Nm (102 lb ft).




12. Position the differential adjuster bearing cup (1) so the it is even in the differential case (2).
13. Using the J 8092 - handle (1) and the J 36603 - installer (2), install the differential adjuster bearing cup in the differential case (3).