Assembly
Fig. 11 Pinion Gear Backlash Check:
1. Assemble differential carrier pinion gears and side gears with washers. Install side gear shafts by hand. Position dial indicator and hold one side gear toward the case, then check side gear backlash, Fig. 11. It should be .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 a press and special service tool No. 09550-10012 or equivalent, press on side bearings.
Fig. 33 Installing New Adjusting Washer & Front Bearing Outer Race:
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 a press and special service tool No. 09250-10011 or equivalent, install front pinion bearing race and adjusting washer, Fig. 33.
Fig. 34 Installing Rear Bearing Outer Race:
6. Using a press and special service tool No. 09608-30012 or equivalent, install rear pinion bearing race, Fig. 34.
Fig. 35 Installing Rear Bearing To Drive Pinion:
7. Using a press and special service tool No. 09502-24010 or equivalent, install rear bearing onto drive pinion, Fig. 35.
Fig. 13 Drive Pinion Installation:
8. Install drive pinion in housing, then using a press and special service tools Nos. 09608-30012 and 09316-60010 or equivalent, install front bearing onto drive pinion, Fig. 13.
9. Install oil slinger. Do not install spacer and oil seal.
Fig. 14 Pinion Flange Installation:
10. Using a press and special service tools Nos. 09223-63010 and 09325-40010 or equivalent, install companion flange onto drive pinion, Fig. 14.
Fig. 9 Pinion Flange Removal:
11. Using special service tools Nos. 09229-50010 and 09330-00021 or equivalent, install companion flange nut, Fig. 9. Torque to 10.8-16.0 inch lbs. on new bearings or 4.3-6.9 inch lbs. on used bearings.
Fig. 36 Installing Side Bearing Outer Race & Adjusting Washer:
12. Using special service tool No. 09608-35014 or equivalent, install side bearing outer race and adjust washer, Fig. 36.
13. Install differential in housing.
14. Using a hammer and special service tool No. 09608-35014 or equivalent, install differential carrier retainers, Fig. 37.
15. Install carrier retainer bolts and torque to 16 ft. lbs.
Fig. 38 Adjusting Washer Thickness Chart:
16. 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, replace the washer on the ring gear tooth side with one of a different thickness from the chart in Fig. 38.
17. Using a torque wrench and special service tool No. 09229-55010 or equivalent, measure total preload. For new bearings, preload should be 3.5-5.2 inch lbs. For used bearings, preload should be 1.7-4.3 inch lbs. If preload is less than specification, replace washer on ring gear tooth side with a thicker one. If preload is greater than specification, replace washer on ring gear tooth side with a thinner one. Changing washer thickness by .0008 inch will change preload .9 in.lbs., Fig. 38.
Fig. 17 Proper Contact Pattern:
18. Coat three or four teeth with suitable grease at three different places. Hold pinion flange firmly and rotate in both directions. Check tooth contact pattern, Fig. 17.
Fig. 18 Adjusting Washer Selection Chart:
19. If contact pattern is not correct, replace adjusting washer installed on front drive pinion rear bearing with a different thickness, Fig. 18.
20. Remove differential retainer, differential case and drive pinion as previously described.
21. Install pinion spacer on drive pinion, drive pinion and front bearing and oil slinger as previously described.
22. Using a press and special service tool No. 09316-60010 or equivalent, press in pinion oil seal until its end is flush with surface of differential carrier.
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 special service tools Nos. 09229-55010 and 09330-00021 or equivalents, tighten pinion nut a little at a time, Fig. 9.
b. Using a torque wrench and special service tool No. 09229-55010 or equivalent, check preload. Preload should be 10.8-16.0 inch lbs. on new bearings or 4.3-6.9 inch lbs. on used bearings.
c. If preload exceeds limit, replace spacer. If preload is below minimum, tighten nut 9 ft. lbs at a time until preload is reached. If torque exceeds 361 ft. lbs., replace spacer and repeat preload procedure. Do not back off the nut to reduce preload.
Fig. 19 Pinion Shaft Runout Check:
25. Check drive pinion shaft runout .39 inch from end of shaft, Fig. 19. Maximum runout should be .0031 inch.
26. Install differential case in carrier.
27. Coat new carrier retainer O-ring with hypoid gear oil and install to carrier retainer.
Fig. 26 Removing Side Bearing Outer Race & Plate Washer:
28. Using a press and special service tools Nos. 09608-32010 and 09608-35014 or equivalents, install new seal into carrier retainer, Fig. 39.
29. Recheck backlash, total preload and tooth contact pattern as previously described.
30. Stake drive pinion nut.
31. Install snap rings to side gear shafts, then using a hammer and brass bar, install side gear shafts.
32. Remove differential carrier from overhaul stand.
33. Place seal packing on carrier cover. Install in vehicle and torque bolts to 34 ft. lbs. Wait one hour, then fill with suitable lubricant.