Assembly

1. Install the thrust washer on each differential side gear and install these in the gear case, Fig. 36.

Fig. 36 Thrust Washer Installation On Side Gears:

2. Through the openings of the gear case, insert each of two pinion gears exactly 180° opposite each other, Fig. 37.

Fig. 37 Pinion Gear Installation:

3. Rotate the gears 0.0° so that the pinion shaft holes of the case come into alignment with the holes in the pinion gears.
4. Insert the pinion shaft through the case and pinion gears.
5. Check backlash of side gear and pinion gear, Fig. 38. Backlash should be 0 to 0.1 mm (0 to 0.004 inch) and must not exceed 0.1 mm (0.004 inch). Adjust as necessary by inserting the proper size side gear thrust washer, Fig. 39.

Fig. 38 Side Gear Backlash Measurement:

Fig. 39 Side Gear Thrust Washer Chart:

6. Install the lockpin to secure the pinion shaft. Stake the lockpin into position with a punch, Fig. 40.

Fig. 40 Pinion Shaft Lockpin Installation:

7. Apply suitable locking compound to rear face of ring gear, then install ring gear to case and torque bolts to 54 - 61 ft.lb.
8. Install each differential bearing to the gear case.
9. Install the differential bearing outer races to their respective bearings, Fig. 41.

Fig. 41 Differential Installation In Housing:

10. Place the differential gear assembly in the carrier, ensuring marks on the face of the pinion and ring gear tooth are in alignment.
11. Note the identification marks on the adjusters and install each to its respective side, Fig. 42.

Fig. 42 Bearing Adjuster Installation:

12. Install the differential bearing caps, ensuring identification marks on the caps correspond with those on the carrier, then install the attaching bolts.
13. Slightly tighten one of the bearing cap bolts on each side and adjust the backlash.