Assembly

1. Clean the components with a suitable solvent and use compressed air to dry all parts. Perform the following before assembly:
- Check for damaged or worn gears and washers.
- Inspect the speedometer drive gear for damage or wear.





2. Install the speedometer drive gear.





3. Use (A) Driver handle T80T-4000-W or a press, along with (B) Bearing Cone Replacer T87C-77000-C to install a new (C) differential bearing.





4. Use (A) Driver handle or a press, along with (B) Bearing Cone Replacer T87C-77000-D to install a new (C) differential bearing (ring gear end).





5. Install the differential side gear thrust washers, differential pinion thrust washers, differential pinion gears, and the differential side gears.
- Rotate the gears to align the differential gears with the pinion shaft hole.





6. Install the differential pinion shaft.





7. Install the differential pinion shaft lock pin. Stake the differential pinion shaft lock pin to prevent it from coming out of the gear case.





8. Use Dial Indicator With Bracketry TOOL-4201-C to measure the backlash of the differential side gears and pinion gears.
(1) Install the left and right front wheel driveshaft and joints into the differential assembly. Support the front wheel driveshaft and joints on V-blocks.
(2) Use Dial Indicator With Bracketry TOOL-4201-C and with Magnetic Base/Flex Arm D78P-4201-C to measure the backlash of the differential side gears and differential pinion gears.
- The standard backlash should be 0.025-0.1 mm (0.001-0.004 inch)
- The maximum backlash is 0.5 mm (0.020 inch). If the backlash is more than allowable, replace the differential as an assembly.