Assembly

Fig. 13 Side gear & thrust washer installation:

Fig. 14 Pinion shaft installation:

Fig. 15 Measuring backlash between side gears & pinion gears:

1. Install the side gears and thrust washers in the differential case, Fig. 13.
2. Lubricate and install pinion gears 180 degrees apart and rotate the gears as an assembly until the pinion gear bores are aligned with the pinion shaft bores in the case.
3. Install pinion shaft, Fig. 14.
4. Using a dial indicator measure the amount of backlash between the side gears and the pinion gears, Fig. 15. One side gear must be held stationary while making this test. If backlash is greater than .003 inch, make necessary adjustments with the thrust washers, available in thickness of .037 to .055 inch. Increasing washer thickness will decrease backlash while decreasing washer thickness will increase backlash.
5. Install lockpin into pinion shaft and caulk its end to prevent loosening.
6. Install ring gear on case making sure their mating surfaces are free of burrs or foreign material. Torque bolt to 47 ft. lbs.
7. Check lateral runout of installed ring gear. Maximum permissible runout is .003 inch. If runout is greater than specified, make certain that dirt or burrs are not holding the ring gear in a cocked position on the case and that the bolts are evenly torqued.

Fig. 16 Differential side bearing installation:

Fig. 17 Check bearing preload & endplay:

8. Install side bearings using installer J-22919 and drive handle J-8092, Fig. 16. Support opposite side of case on pilot J-2241-11 to prevent bearing damage.
9. Determine differential side bearing preload and backlash as follows:
a. Position differential case assembly less side bearing shims into the side bearing shims into the side bearing bores of the carrier.
b. Using two sets of feeler gauges, insert feeler stock of sufficient thickness between each bearing outer race and the carrier to remove all endplay, Fig. 17. Make certain the feeler stock is pushed to the bottom of the bearing bores.
c. Mount dial indicator J-8001 on carrier so indicator stem is at right angles to a tooth on the ring gear.
d. Adjust feeler gauge thickness from side to side until ring gear backlash is .005 to .007 inch (.006 inch is desired).
e. With zero endplay and correct backlash established, remove feeler gauge packs, determine thickness of shims required and add .002'' to each shim pack to provide side bearing preload.
f. Remove case assembly and both side bearings using J-22588 with adapter leg J-22939 and pilot J-2241-11.
g. Install shim packs with respective side bearing using installer J-22919, driver handle J-8092 and pilot J-2241-11.
10. Position case assembly and outer races in the carrier. Use a soft faced hammer to drive the case into the carrier until the side bearing outer races bottom in their bores.
11. Install the side bearing caps in their original location and torque bolts to 35 ft. lbs.
12. Rotate case assembly several times to seat bearings. Check backlash and preload using a torque wrench on a ring gear attaching bolt. Torque required to turn case should be 20 to 30 inch lbs. for new bearings or 10 to 20 inch lbs. for used bearings. If torque is not correct, it will be necessary to re-shim the side bearings.
13. Install torque tube assembly.
14. Install axle shafts.