Differential Case: Service and Repair

1. On models less limited slip differential, install side gears and thrust washers in differential case.

Fig. 22 Positioning pinion gears:

2. Position pinion gears 180° apart, Fig. 16, then roll gears into position, making sure they are aligned, to allow installation of pinion shaft.
3. Place thrust block between pinion gears and drive pinion into place. Make sure the lockpin hole in the cross shaft lock aligns with hole in case.
4. Check backlash between differential gears and pinion gears. If backlash is greater than .003 inch, make necessary adjustments with thrust washers. Thrust washers are available in thicknesses of .041, .045, .049 and .053 inch. Increasing washer thickness will decrease backlash. Decreasing washer thickness will increase backlash.

Fig. 23 Installing lockpin:

5. Install cross shaft lockpin, Fig. 17, then caulk end to avoid loosening.

Fig. 18 Dimensions A, B, & C Measurement:

6. On models with limited slip differential, to set differential housing to carrier housing clearance, measure dimensions A, B and C, Fig. 18, then place pinion cross shaft in pressure rings, install friction plates and discs on pressure rings and measure dimension D Fig. 19.
7. Measure thickness of a spring disc and multiply by 4, this will equal dimension E. Using formula (A - B) + C - (D + E) = X, select friction discs or plates to adjust dimension D to give a result of 0.002 to 0.008 inch for X. Variance in thickness of friction discs or plates should not exceed 0.020 inch.

Fig. 21 Dimensions B,F & G Measurement:

8. To set backlash, proceed as follows:
a. Place pinions on cross shaft, then install cross shaft assembly and side gears into pressure rings.
b. With side gear thrust washers held into place, measure dimension H Fig. 20.
c. Using the formula (F - B) + (G - H) = Y, select thrust washers to adjust dimension H to give a result of 0.002 to 0.008 inch for Y.
d. Measure dimensions F and G Fig. 21.
e. Select thrust washers so that variance in dimension of each half of the assembly does not exceed 0.002 inch.

Fig. 22 Spring Disc Position:

9. Refer to Fig. 22. for assembly sequence. Ensure spring discs are installed correctly, Fig. 22.

Fig. 24 Ring gear bolts tightening sequence. Rear differentials:

Fig. 24 Ring Gear Bolts Tightening Sequence:

10. Clean ring gear bolts then apply Loctite to threaded portion of bolts. Install ring gear, then install and torque bolts to 80-87 ft. lbs. for rear differentials or 44-58 ft. lbs. for front differentials in sequence shown in Figs. 23 and 24.