Assembly

Thrust Washer Thickness:

1. Select suitable thrust washers from chart, See Thrust Washer Thickness Table, that will bring backlash to .0020-.0079 inch, then install thrust washers into differential case.

2. Drive in straight pin, using a hammer and suitable drift, through case and hole in pinion shaft, then stake pin to differential case.

3. Install side bearings using tool No. 09608-30012.

4. Clean mating surfaces of differential case, then heat ring gear in a suitable oil bath to approximately 212°F.

5. Quickly install ring gear onto differential case, aligning matchmarks on gear and case.

6. Apply a suitable lubricant to ring gear attaching bolts then install lock plates and attaching bolts. After ring gear cools down Torque bolts uniformly to 71 ft. lbs.

7. Stake lock plates using a hammer and suitable drift.

8. Check ring gear runout. Maximum runout should be .0028 inch

9. Temporarily adjust drive pinion preload as follows:
a. Install drive pinion and front bearing.
b. Install companion flange using tool No. 09557-22022.
c. Retain companion flange using tool No. 09330-0021, then adjust drive pinion preload to 6.9-9.5 inch lbs

10. Place bearing outer races on their respective bearings, then insert case into carrier.

11. Install adjusting nuts on their respective carrier, ensuring backlash exists between ring gear and drive pinion.

12. Align mating marks on bearing caps and carrier, then rotate cap bolts 2-3 turns and manually depress cap.

13. Torque cap bolts to 58 foot lbs. back off bearing cap bolts until adjusting nuts will turn. Tighten adjusting nut on ring gear side until ring gear backlash is approximately .008 inch.

Fig. 7 Differential Bearing Preload Adjustment. Models w/removable Carrier:

14. Tighten adjusting nut from drive pinion side as shown, See Image, then check for backlash. If tightening nut causes backlash, loosen nut until backlash is eliminated.

15. Install a suitable dial indicator on top of adjusting nut, then adjust side bearing for zero preload, or until indicator begins to move. Tighten nut 1-1/2 notches from zero preload position.

16. Adjust ring gear backlash to .0051-.0071 inch, by rotating both left and right adjusting nuts equal amounts, then torque bearing cap bolts to 58 ft. lbs.

17. Measure total preload. Side bearing preload should be 3.5-5.2 inch lbs. Add pinion preload for total preload. Backlash should be .0051-.0071 inch.

Fig. 9 Ring Gear & Pinion Tooth Contact Inspection:

Fig. 24 Pinion shaft shim selection chart. 1987-88 Van w/4 wheel drive:

18. Inspect gear tooth contact as shown, See Image, If contacting pattern is not correct, select a suitable shim from chart, See Plate Washer Thickness Chart, that will ensure proper contact. Note; Shims for Van models are the same as those available for 1/2 ton Pickup.

19. Install new bearing spacer and front bearing.

20. Install oil slinger, then drive in new oil seal to a depth of .059 inch

21. Install companion flange, using tool No. 09557-22022, then apply a suitable lubricant to new nut. Retain companion flange, using tool No. 09330-00021, then install nut and torque to 80 ft. lbs.

22. Check drive pinion preload. Drive pinion preload should be 5.2-8.7 inch lbs.

23. If preload is greater than specified, replace bearing spacer. If preload is less than specified torque nut 9 ft. lbs. at a time until specified preload is obtained. If maximum torque is exceeded during tightening procedure, replace bearing spacer and repeat preload adjustment. Maximum torque specs; 174 foot lbs.

24. Check companion flange deviation. Deviation in any direction should not exceed .0039 inch.

25. Stake drive pinion nut.

26. Install bearing cap adjusting nut lock, then torque attaching bolt to 9 ft. lbs.