Part 2
Item 18 and 20: Inner and Outer Pinion Bearing Cup Assembly Note1. CAUTION: Always install new differential pinion bearings when installing new differential drive pinion bearing cups.
Lubricate the new differential drive pinion bearing cups.
2. Using the special tools, install the differential drive pinion bearing cups.
Item 17: Pinion Position Shim and Item 16: Inner Pinion Bearing Assembly Note
1. NOTE: Apply a light film of oil to the differential pinion bearings before installing them.
Assemble and position the following in the differential housing.
1 Position the Screw.
2 Position the Aligning Adapter.
3 Position the inner differential pinion bearing.
4 Position the Gauge Disc.
5 Position the Gauge Block.
6 Position the outer differential pinion bearing.
7 Thread on the Handle.
2. Using a Nm (inch-pound) torque wrench, tighten the Handle.
3. NOTE: Offset the Gauge Block to obtain an accurate reading.
Rotate the Gauge Block several half turns to make sure the differential pinion bearings seat correctly. Position the special tool as shown.
4. Install the special tool and the paper shipping tags.
1 Position the special tool and the paper shipping tags.
2 Install the differential bearing caps.
3 Install the bolts.
5. NOTE: Use a feeler gauge, or flat, clean drive pinion position shims as a measuring device.
NOTE: Selection of a shim that is too thick results in deep tooth contact at final assembly. Do not attempt to force the gauge or shim between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.
Using a feeler gauge, or a flat, clean drive pinion position shim, measure between the Gauge Block and the Gauge Tube. Record the measurement.
^ Remove the special tools after determining the correct shim thickness.
6. Select the correct thickness drive pinion position shim.
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^ New drive pinion position shims are available in these sizes:
^ If installing a new gearset, notice the plus (+), minus (-), or zero (0) etching on the new drive pinion, and adjust the thickness of the new shim. If etching is plus (+), subtract the number from the gauged shim thickness. If etching is minus (-), add the number to the gauged shim thickness.
7. Install the pinion position shim and the differential pinion bearing.
^ Using the special tool and a suitable press, seat the differential pinion bearing firmly against the pinion position shim.
Item 14: Differential Case Assembly Note
1. Install the special tools.
^ Position the clutch housing gauge needle in the differential carrier spreader adapter hole.
2. CAUTION: Overspreading can damage the differential housing.
Spread the differential housing to the specification.
3. Remove the special tools.
4. NOTE: Push the differential case downward to fully seat the differential bearing cups in the differential housing.
Install the differential bearing cups and the differential case in the differential housing.
1 Position the differential bearing cups on the differential bearings.
2 Lower the differential case in place.
5. CAUTION: Do not tighten the bolts to specification at this time.
Install the differential bearing caps in their original positions.
1 Position the differential bearing caps.
2 Install the bolts hand-tight.
6. Remove the special tools.
7. Tighten the bolts.
8. Verify that the differential case rotates freely.
9. Using the special tools, measure the backlash at three equally spaced points on the differential ring gear.
1 Mount the special tool.
2 Position the special tool.
3 Zero the indicator.
4 Turn the differential ring gear without turning the pinion gear. Record the measurement.
^ The backlash tolerance is 0.13 mm (0.005 inch) to 0.20 mm (0.008 inch) and cannot vary more than 0.05 mm (0.002 inch) between points checked. A backlash variation of more than 0.005 mm (0.002 inch) indicates gear/case runout.
^ If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount.
Item 9: Axle Shaft Bearing Assembly Note
1. Using the special tools, install the axle tube bearing.
Item 8: Axle Shaft Oil Seal Assembly Note
1. Using the special tools, install the axle shaft oil seal.
Item 4: Pinion Oil Seal Assembly Note
1. NOTE: Lubricate the pinion seal.
Using the special tool, install the pinion seal.
Item 2: Pinion Flange Assembly Note
1. CAUTION: Never use a metal hammer on the pinion flange or install the flange with power tools.
NOTE: Lubricate the pinion flange splines.
Align the index marks. Using the special tool, install the pinion flange.
Item 1: Pinion Nut and Washer Assembly Note
1. CAUTION: Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if preload reduction is necessary.
Using the special tool to hold the pinion flange, tighten the nut to set the preload.
^ Tighten the nut, rotating the pinion occasionally to make sure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. The final reading must be 0.56 Nm (5 inch lbs.) more than the initial reading taken during removal.