Assembly
Fig. 11 Pinion Gear Backlash Check:
1. Assembly differential carrier pinion gears and side gears with washers. Install side gear shafts by hand. Set up dial indicator and hold one side gear toward the case, then check side gear backlash, Fig. 11. It should be between .0020-.0079 inch. If not, adjust by changing thrust washers, the thicknesses available are .063, .067 and .071 inch. Remove side gear shafts and dial indicator.
2. Install straight pin and stake to differential case.
3. Heat ring gear in boiling water. Remove and let set until water has evaporated, then place on differential. Align holes, install new bolts, do not tighten. After ring gear has cooled, tighten new set bolts with thread locker. Torque bolts to 47 ft. lbs. then turn 90°.
4. Using side bearing installer No. 09550-10012, or equivalent, press on side bearings.
Fig. 12 Adjusting Washer Installation:
5. When installing pinion bearings, always install a new adjusting washer the same size as removed, later check tooth pattern and install different sized washers as necessary. Using race installer No. 09250-10011, or equivalent, press in rear pinion bearing race and adjusting washer, Fig. 12.
6. Using race installer No. 09608-30012, or equivalent, press in front pinion bearing race.
7. Using pinion bearing installer No. 09710-30020, or equivalent, press bearing onto drive pinion.
Fig. 13 Drive Pinion Installation:
8. Install drive pinion in housing. Using bearing installer tools Nos. 09223-63010 and 09316-60010, or equivalent, press front bearing onto drive pinion, Fig. 13.
Fig. 14 Pinion Flange Installation:
9. Install oil slinger. Do not install spacer and oil seal. Using flange installation tools Nos. 09223-63010 and 09325-40010, or equivalent, press companion flange onto drive pinion, Fig. 14.
Fig. 9 Pinion Flange Removal:
10. Using nut tightening tools Nos. 09229-50010 and 09330-00021, or equivalent, tighten nut carefully, Fig. 9. Torque to 10.8-16.0 in. lbs. for new bearings. Torque to 4.3-6.9 in. lbs. for used bearings.
11. Install differential in housing.
12. Using bearing race installer tools Nos. 09550-10012 and 09608-10010, or equivalent, install bearing race in drive pinion side of housing. Tap down with hammer until half of the snap ring groove is showing.
Fig. 15 Installing Outer Race:
13. Install special service tool No. SST 09571-50010, or equivalent, to differential housing and lightly tighten bolt, Fig. 15.
14. Using bearing race installer tools Nos. 09550-10012 and 09608-10010, or equivalent, to install race on ring gear side of housing. Install until race makes contact with rollers of the side bearing.
15. Fit the thinnest snap ring to the ring gear side, .1441 inch.
Fig. 5 Dial Indicator Placement For Spreading Housing:
16. Install dial indicator on housing, Fig. 5. Tighten special service tool bolt to spread housing .0039 inch. Rotate ring gear back and forth to settle bearings.
17. Measure backlash at three locations and note values. The average value should be .0031-.0051 inch. The difference between maximum and minimum measured values must be .0020 inch or less. If backlash is not within specifications, select a new snap ring as follows:
a. Loosen special service tool bolt until it separates from side bearing race.
b. Using race installation tool No. 09550-10012 and 09608-10010, or equivalent, tap in race on ring gear side.
Fig. 16 Snap Ring Thickness Chart:
c. Using snap ring pliers No. 09905-00030, or equivalent, remove ring gear side snap ring. Using snap ring pliers, install a new snap ring with a different thickness, Fig. 16.
d. Tap on differential housing to eliminate strain.
e. Install dial indicator on carrier, Fig. 5.
f. Tighten special service tool bolt and spread carrier .0039 inch.
g. Measure ring gear backlash. If it does not fall within specifications, repeat step 17 again.
18. Adjust preload as follows:
a. Install dial indicator on carrier, Fig. 5.
b. Tighten special service tool until housing spreads .0039 inch.
c. Using snap ring pliers No. 09905-00030, or equivalent and install thickest snap ring that will fit in drive pinion side.
d. Remove dial indicator, loosen special service tool, tap on housing to relieve strain and confirm backlash reading. If there is no backlash at even one point, replace snap ring on drive pinion side with a thicker one.
e. Using pinion nut tool No. 09229-55010, or equivalent and torque wrench, measure pinion preload. For new bearings, it should be 3.5-5.2 in. lbs. For used bearings, it should be 1.7-4.3 in. lbs. If preload is less than specification, replace snap ring on drive pinion side with a thicker one. If preload is greater than specification, replace snap ring on ring gear side with a thinner one. Changing snap ring thickness by .0008 inch will change preload .9 in. lbs.
f. Measure backlash. If backlash is greater than specified, replace snap ring on ring gear side with a thicker one and replace snap ring on pinion side with a thinner one to the same extent that the ring gear side is thicker. If backlash is less than specified, replace snap ring on ring gear side with a thinner one and replace snap ring on pinion side with a thicker one to the same extent that the ring gear side is thinner. Backlash will change .0008 inch for every .0008 inch in snap ring variation. Keep backlash as close to .0039 inch as possible.
g. Recheck total preload.
Fig. 17 Proper Contact Pattern:
Fig. 18 Adjusting Washer Selection Chart:
19. Coat three or four teeth at three different places. Hold pinion flange firmly and rotate in both directions. Check tooth contact pattern, Fig. 17.
20. If contact pattern is not correct, replace adjusting washer with a new one, Fig. 18.
21. Remove drive pinion as previously described and install pinion spacer.
22. Using seal installer No. 09316-63010 or equivalent, install pinion oil seal.
23. Install pinion drive gear and pinion flange as previously described.
24. Adjust pinion preload as follows:
Fig. 9 Pinion Flange Removal:
a. Coat threads of flange and nut with hypoid gear oil. Using pinion flange nut tools Nos. 09229-55010 and 09330-00021, or equivalent, torque pinion nut to 108 ft. lbs, Fig. 9.
b. Using pinion nut tool No. 09229-55010, or equivalent and torque wrench, check preload. With new bearings, preload should be between 10.8-16.0 in. lbs. With used bearings, preload should be between 4.3-6.9 in. lbs.
c. If preload is too great, replace spacer. If preload is not enough, tighten nut 9 ft. lbs at a time until preload is reached. If torque exceeds 361 ft. lbs., replace spacer and repeat preload procedure.
Fig. 19 Pinion Shaft Runout Check:
25. Check drive pinion shaft runout at .39 inch from end of shaft, Fig. 19. Maximum runout should be .0031 inch.
26. Install carrier in housing as previously described.
27. Install side bearing races as previously described.
28. Install same snap rings as determined under tooth contact pattern, as described previously.
29. Recheck backlash, total preload and tooth contact pattern.
30. Stake drive pinion nut.
31. Using seal installer No. 09223-63010 or equivalent, install housing side seals.
32. Install side gear shafts, tap in with plastic hammer. Install two new snap rings.
33. Place seal packing on carrier cover. Place on vehicle and torque bolts to 34 ft. lbs. Wait one hour then fill with 1.4 qts. of SAE 80w-90 gear oil.