Differential Carrier Assembly Final Assembly (9.25 Inch HD Axle)
Differential Carrier Assembly Final Assembly (9.25 Inch HD Axle)
Special Tools
* EN 44215 - Installer
* J 5590 - Installer
* J 8001 - Dial Indicator Set
* J 8614-A - Flange and Pulley Holding Tool
* J 25025 - Guide Pins
* J 33842 - Bearing Installer
* J 36366-A - Pinion Oil Seal Installer
* J 36609 - Side Bearing Installer
* J 36614 - Inner Pinion Bearing Installer
For equivalent regional tools, refer to Special Tools Front Drive Axle.
1. Install the selective shim (1) on the drive pinion gear.
2. Using the J 36614 - installer (1), install the front differential pinion gear bearing (2).
3. Install the NEW collapsible spacer (1) on the drive pinion gear.
4. Lubricate the inner and the outer pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations Maintenance.
5. Install the outer drive pinion bearing cup into the differential housing. Refer to Front Differential Drive Pinion Gear Bearing Cup Installation (9.25 Inch HD Axle) Front Differential Drive Pinion Gear Bearing Cup Installation (9.25 Inch HD Axle).
6. Using the J 36366-A - installer (1), install the front differential drive pinion gear seal (2).
7. Adjust the drive pinion gear depth. Refer to Pinion Depth Adjustment (8.6, 9.25 Inch Axle) Pinion Depth Adjustment (8.6, 9.25 Inch Axle)Pinion Depth Adjustment (9.25 Inch HD Axle) Pinion Depth Adjustment (9.25 Inch HD Axle).
8. Install the front differential housing (2) in a soft jawed vise.
9. Install the drive pinion gear (1) in the differential housing.
10. Using a soft faced hammer and supporting the drive pinion gear from the inside, lightly tap the front differential drive pinion gear yoke (2) until the threads of the drive pinion gear show through.
11. Install the washer (1) on the front drive pinion gear.
12. Install the old drive pinion gear nut.
Note: DO NOT use air tools for this procedure. Use ONLY HAND TOOLS.
13. Using the J 8614-A - holding tool and a ratchet wrench, draw the front differential drive pinion gear yoke 3/4 of the way onto the drive pinion gear.
14. Remove the old drive pinion gear nut and replace with the NEW drive pinion gear nut.
Note: Rotate the drive pinion while tightening the drive pinion nut in order to seat the bearings.
15. Tighten the NEW drive pinion nut until the end play is just taken up.
Note: If the rotating torque is greater than the specifications required, the collapsible spacer will have to been replaced.
16. Using an inch pound torque wrench (1), measure the rotating torque of the drive pinon which should be 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for NEW bearings.
17. If the rotating torque reading is below 1.0 Nm (10 lb in) for used bearing or 1.7 Nm (15 lb in) for the NEW bearings, re-install the J 8614-A - holding tool and continue to tighten the drive pinion nut until the required specifications are met 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for NEW bearings.
Note: Recheck the rotating torque if necessary.
18. Once the specified torque specifications have been reached, rotate the drive pinon several times to ensure that the drive pinon bearings are seated.
19. Install the differential adjuster (1) in the differential carrier (2).
20. Position the J 8001 - indicator (2) and the J 25025 - guide pins (3) on the differential housing.
Note: Ensure that the gauge is aligned with the gear rotation and square to the tooth angle.
21. Preload the J 8001 - indicator (2) approximately 1/2 turn and zero the gauge.
22. Using a 57 mm 12 point socket, turn the right side differential adjuster (1) clockwise until 0.0254-0.0762 mm (0.001-0.003 in) of backlash can be measured on the ring gear and the drive pinon gear.
23. Using a 57 mm 12 point socket, turn the left differential adjuster (1) to preload the adjuster bearings against the differential bearing cups.
24. Tighten the differential adjuster nut obtain a total torque to rotate of the SUM of the 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for NEW bearings.
25. Rotate the drive pinion several times in order to seat the drive pinion and differential adjuster bearings.
26. Using a inch pound torque wrench and measure the rotating torque of the differential assembly which should be 1.99-4.2 Nm (17-37 lb in) for NEW bearings and 1.29-3.1 Nm (11-27 lb in) for used bearings.
27. If the rotating torque measurement is below 1.29-3.1 Nm (11-27 lb in) for used bearings or 1.99-4.2 Nm (17-37 lb in) for NEW bearings, adjust the differential side bearing preload using the following steps:
1. Place an alignment mark between the differential adjuster nut and the differential carrier case for the left and right sides.
2. Turn the differential adjuster in or clockwise.
3. Using a inch pound torque wrench, measure the rotating torque of the differential assembly.
4. Compare the new measurement to the specifications in step 8. If the rotating torque of the differential assembly is not within specifications, continue to tighten the left and right differential adjusters until the rotating torque of the differential assembly is within specifications.
28. If the rotating torque measurement is above 3.1 Nm (27 lb in) for used bearings or 4.2 Nm (37 lb in) for NEW bearings, adjust the differential side bearing preload using the following steps:
1. Place an alignment mark between the differential adjuster nut and the differential carrier case for the left and right sides.
2. Turn the differential adjuster out or counter clockwise.
3. Using a inch pound torque wrench, measure the rotating torque of the differential assembly.
4. Compare the new measurement to the specifications in step 8. If the rotating torque of the differential assembly is not within specifications, continue to tighten the left and right differential adjusters until the rotating torque of the differential assembly is within specifications.
Note: Recheck the rotating torque and adjust if necessary.
29. Once the specified rotating torque is obtained, rotate the differential assembly several times to ensure that the bearings have seated.
30. Once the bearing preload and drive pinion to ring gear backlash is within specifications, perform a gear tooth contact pattern check to ensure proper contact between the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection Gear Tooth Contact Pattern Inspection.
31. Install the differential adjuster lock ring (1) flush with differential housing.
32. Install the inner axle shaft in a vise.
33. Using the J 36609 - installer (1) and the J 8092 - handle (2), install the inner bearing.
34. Using the EN 44215 - installer (1) and the J 8092 - handle (2), install the inner axle shaft seal.
35. Using a soft face mallet, install the inner axle shaft (1).
36. Install the thrust washer (5), NEW retaining ring (6), on the inner axle shaft (1).
37. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment (8.6 9.25 Inch Axles) Inner Axle Shaft Shim Adjustment (8.6 9.25 Inch Axles)Inner Axle Shaft Shim Adjustment (9.25 Inch HD axle) Inner Axle Shaft Shim Adjustment (9.25 Inch HD axle).
38. Install the correct clutch gear shim (8), clutch sleeve (7), clutch fork assembly (10), and the clutch fork inner spring (9) in the inner axle housing.
39. Install the rear axle housing cover gasket (3), rear axle housing cover (2).
Caution: Refer to Fastener Caution Fastener Caution.
40. Install the rear axle housing covers bolts (1) and tighten to 40 Nm (30 lb ft).
Note: Ensure that the axle shaft seal is evenly positioned in the rear differential housing.
41. Position the rear axle shaft seal (1) in the rear differently housing.
42. Using the EN 44215 - installer (2) and the J 8092 - handle (1), install the rear axle shaft seal.
43. Install the front drive axle inner shaft (1).
44. Using the J 33842 - installer (2) and a hammer (1), install the front drive axle clutch shaft bearing.
45. Install the front drive axle clutch shaft (1) into the differential side gear (2).
46. Install the front drive axle inner axle assembly (2), gasket (3), the bolts (1).
47. Tighten the bolts (1) to 65 Nm (48 lb ft).
48. Apply a small amount of the correct sealant to the threads of the actuator (1). Refer to Adhesives, Fluids, Lubricants, and Sealers Front Drive Axle.
49. Install the front drive axle actuator (1) and tighten to 30 Nm (22 lb ft).