Assembly

Reverse disassembly procedure for reassembly, noting the following:
1. The bevel pinion and bevel gear are replaced as a set. Even when only the bevel pinion or bevel gear replacement is necessary, ensure to replace both as a set.
2. When installing differential pinion shaft into differential case, ensure to install longer end of shaft first into pinion joint.
3. The bolts securing bevel gear to differential case are subject to shear stress, since drive is transmitted by these bolts from gear to case. For this reason, they are special bolts made from chrome steel and must never be replaced by common bolts. Apply Loctite to threads of bolts before installing them.
4. Using bearing installer 09940-53111 and a press, install differential side bearings into differential case.
5. A press must be used to install two tapered roller bearings on bevel pinion. Outer races are press fitted into the differential carrier and inner races onto the pinion.
6. After installing bevel pinion, spacer, bearings and universal joint flange to carrier, and completing bevel pinion bearing preload adjustment, stake bevel pinion nut to prevent it from loosening.
7. When installing side bearing caps, ensure match marks scribed at the time of disassembly align, then after completing bevel gear backlash adjustment, torque cap bolts to 51-72 ft. lbs.