Assembly

Assembly





1. Using the special tool, install the differential drive pinion bearing cups.
^ Position the bearing cups on the special tool.
^ Position the special tool and the bearing cups in the differential housing.
^ Tighten the special tool to fully seat the bearing cups in the bores.

2. NOTE: If a feeler gauge of the specification shown can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.





Make sure the differential pinion bearing cups are correctly seated.

3. CAUTION: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly.

NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.





Install the differential pinion bearings and special tools as shown.

4. NOTE: This step duplicates differential pinion bearing preload.





Thread the special tool onto the screw.
^ Tighten to 2.2 Nm (20 inch lbs.).

5. CAUTION: Offset the special tool to obtain an accurate reading.





Rotate the special tool several half turns to seat the differential pinion bearings. Position the special tool as shown.





6. Install the special tool.
^ Position the special tool in the differential housing differential bearing seat.





7. Install the differential bearing cap, then install the differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).





8. Use a differential pinion bearing adjustment shim as a gauge for shim selection. Check the differential pinion bearing adjustment shim thickness between the Gauge Block and the Gauge Tube. A slight drag indicates correct differential pinion bearing adjustment shim selection.
9. Remove all of the special tools.

10. CAUTION: Use the same differential pinion bearings and differential pinion bearing adjustment shim from the differential pinion bearing adjustment shim selection procedure for final assembly.

Position the differential pinion bearing adjustment shim and the inner pinion bearing on the differential pinion stem.





11. Using the special tools and a suitable press, firmly seat the differential pinion bearing adjustment shim and inner pinion bearing on the differential pinion stem.

12. CAUTION: Make sure the splines on the differential pinion stem are free of burrs. If burrs are evident, remove them using a fine crocus cloth.





Place a new drive pinion collapsible spacer on the differential pinion stem against the differential pinion stem shoulder.
13. Install the differential pinion gear with the drive pinion collapsible spacer in the differential housing.
14. Install the outer pinion bearing and rear pinion oil seal slinger.

15. CAUTION: Installation without the correct tool can result in early rear pinion oil seal failure.

CAUTION: If the rear pinion oil seal becomes misaligned during installation, remove it and install a new one.

NOTE: Coat the rear pinion oil seal lips with grease.





Using the special tool, install the new rear pinion oil seal.





16. Using the special tools, install the rear axle pinion flange.

17. CAUTION: Do not, under any circumstance, loosen the differential drive pinion nut to reduce differential pinion bearing preload. If it is necessary to reduce differential pinion bearing preload, install a new drive pinion collapsible spacer and differential drive pinion nut.

CAUTION: Remove the special tool while taking differential pinion bearing preload readings with the Nm (inch lbs.) torque wrench.





Use the special tool to hold the rear axle pinion flange while tightening the differential drive pinion nut.
^ Rotate the differential pinion gear occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the differential pinion gear with a Nm (inch lbs.) torque wrench.





18. Tighten the differential drive pinion nut to set the differential pinion bearing preload.





19. Install the special tools on the differential case.





20. Position the special tool on the differential case in the differential housing.





21. Install a unique set-up selective snap ring with a thickness of 2.54 mm (0.100 inch).

22. NOTE: Repeat this step until obtaining a consistent reading.

Measure the total end play.
^ Attach the special tools and position the indicator tip on the machined surface of the differential case flange.
^ Move the differential case to the left and the right (as far as possible).
^ Record the reading in Line A.








Differential Bearing Shim Selection Chart

23. Remove the dial indicator and the differential case from the differential housing.





24. Install the differential ring gear.
1 Place the differential ring gear on the differential case.
2 Hand start 3 differential ring gear bolts to align the holes in the differential ring gear and the differential case.
3 Place the differential case and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
4 Press the differential ring gear into place.





25. Install the remaining differential ring gear bolts. Apply sealer to the ring gear bolt threads.
^ Tighten to 120 Nm (89 ft. lbs.).





26. Place the differential case with the special tool into the differential housing.





27. Install the special tool.





28. Measure the end play.
^ Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
^ Rock the differential ring gear to allow full mesh with the drive pinion gear.
^ With the gears in full mesh, set the special tool to zero.
^ Move the differential case as far as possible to the left and note the reading.
^ Record the reading on the differential bearing shim selection procedure Line B.
- Remove the special tool.





29. Remove the differential case from the differential housing.





30. Using a suitable press, press the differential bearings on the differential case.





31. Place the differential case and differential bearing cups in the differential case.

32. NOTE: Select the correct size selective snap ring using the differential bearing shim selection chart.

NOTE: To determine the thickness of the selective snap ring to be used, subtract Line B from Line A. Add Lines D and E to the difference. This is the thickness of the selective snap ring required.





Place the selective snap ring in the differential housing.

33. NOTE: Select the correct size selective bearing shim using the differential bearing shim selection chart.

NOTE: To determine the thickness of the differential bearing shim to be used, add Lines A, F and G. Subtract Lines C and D from the sum. This is the thickness of the differential bearing shim required.





Position the differential bearing shim indicated by the differential bearing shim selection chart.





34. Using the special tools, seat the differential bearing shim in the differential housing.





35. Install the differential bearing cap, then the differential bearing cap bolts in the original location.
^ Tighten to 105 Nm (77 ft. lbs.).
36. Lubricate the lips of the halfshaft housing seal with grease.





37. Using the special tools, measure the differential ring gear backlash at 4 equally spaced points.
^ Attach the special tool.
^ Position the special tool tip centrally on a drive tooth.
^ Zero the indicator.
^ Turn the differential ring gear without turning the differential pinion gear. Record the indicator reading. The allowable backlash is 0.127 mm (0.005 inch) to 0.228 mm (0.009 inch) and must not vary more than 0.076 mm (0.003 inch) between points measured. A backlash variation of more than 0.076 mm (0.003 inch) between points checked indicates gear/case runout.
- If backlash is within specifications, install the axle assembly.
- To correct for a high or low backlash, proceed as follows.








38. To correct for high or low backlash, increase or decrease the thickness of the differential bearing shim and decrease or increase the thickness of the selective snap ring by the same amount. Refer to the following tables when adjusting the backlash. When the backlash is within specifications, install the differential assembly.








Differential Snap Ring Size Chart -13277-








Differential Shim Size Chart -4067-





39. Using the special tools, install the halfshaft housing seal.
40. Apply marking compound and rotate the differential assembly 5 complete revolutions.
41. Verify an acceptable pattern check.





42. Remove the differential assembly from the special tool.

43. CAUTION: The differential housing cover must be installed within 15 minutes of application of the sealant.

CAUTION: Allow the Silicone Gasket and Sealant to cure for 1 hour before filling the axle with lubricant.

Apply a continuous bead of Silicone Gasket and Sealant to the differential housing cover mounting surface, then install the differential housing cover.
44. Install the rear axle assembly.
45. Fill the axle with the specified amount of specified lubricant.