Differential Carrier Assembly Assemble (8.25 Inch Axle Lock Ring Style)
Differential Carrier Assembly Assemble (8.25 Inch Axle Lock Ring Style)
Special Tools
* J 8092 Universal Driver Handle-3/4 in 10
* J 8614-01 Flange and Pulley Holding Tool
* J 35512 Inner Pinion Bearing Installer
* J 36366 Pinion Oil Seal Installer
* J 36599-A Side Bearing Nut Wrench
* J 36603 Side Bearing Cup Installer
* J 36609 Axle Tube Bearing Installer
* J 36612 Output Shaft Bearing Installer
* J 36614 Pinion Bearing Installer
* J 36615 Side Bearing Nut Wrench
* J 36616 Adjuster Nut Wrench
1. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.
2. Using the J 35512 , install the inner pinion bearing onto the pinion gear.
3. Install the new collapsible spacer onto the pinion gear.
4. Lubricate the inner and the outer pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations .
5. Install the outer pinion bearing into the differential carrier case half.
6. Install the oil seal by doing the following:
1. Install the differential carrier case half into a vise. Place a shop towel in a vise in order to protect the differential case.
2. Using the J 36366 , install the seal. Ensure that the seal flange is seated on the axle housing surface
7. Apply sealant to the splines of the pinion yoke. Use the correct sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers (Fluid Type Specifications) .
8. Install the pinion gear, with the inner pinion bearing an the new collapsible spacer, into the left differential carrier case half.
9. Install the pinion yoke.
Caution: Refer to Pinion Flange/Yoke Installation Caution (Pinion Flange/Yoke Installation Caution) .
10. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft by threads show through the yoke.
11. Install the new pinion nut and the new washer. If the pinion nut cannot be installed, perform the following steps in order to seat the pinion yoke onto the pinion so that the washer and new pinion nut can be installed:
1. Remove the pinion nut washer.
2. Install the old pinion nut.
3. Tighten the nut until a few of the shaft threads show through the nut so that the washer and new pinion nut can be in stalled.
4. Remove the old pinion nut.
5. Install the pinion nut washer.
6. Install the new pinion nut.
12. Install the J 8614-01 onto the pinion yoke as shown.
Caution: Refer to Fastener Caution (Fastener Caution) .
Note
If the rotating torque exceeded, the pinion will be removed and a new collapsible spacer installed.
13. Tighten the pinion nut while holding the J 8614-01 .
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut in order to seat the bearings.
14. Remove the J 8614-01 .
15. Using an inch pound torque wrench, measure the rotating torque of the pinion.
The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings, 1.7-3.4 Nm (15-30 lb in) for new bearings.
16. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15 lb in) for new bearings, reinstall the J 8614-01 and continue to tighten the pinion nut.
The rotating torque of the pinion should be 1.0-2.3 Nm (10-20 lb in) for used bearings, 1.7-3.4 Nm (15-30 lb in) for new bearings.
17. Once the specified torque is obtained, rotate the pinion several time to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.
18. Remove the J 8614-01 .
19. Assemble the differential adjuster nut into the differential adjuster nut sleeve until it is fully seated.
20. Using the J 36614 (2) and the J 8092 (1), install the inner shaft bearing inner shaft bearing onto the differential bearing adjuster for the 8.25 inch S4WD axle left and right side, 8.25 inch F4WD axle left.
21. Using the J 36614 (2) and the J 8092 (1), install the left and right side differential adjuster nut assembly into the differential carrier case.
22. Using the J 8092 (1) , install the left and right differential case side bearing cups into the differential carrier case.
23. Install the differential case assembly into the left differential carrier case half.
Note
The sealing surfaces of the differential carrier halves must be free of grease and oil to ensure that the gasket will seal properly.
24. Install the differential carrier case gasket (3).
25. Install the differential carrier case (2) half to the left differential carrier case half. If the carrier case halves do not make complete contact, use the J 36599-A in order to back out right differential adjuster nut sleeve until the differential carrier case halves make contact.
26. Install the differential carrier case bolts (1).
Tighten the differential carrier case bolts to 73 Nm (54 lb ft).
27. Install the differential carrier assembly into a vise.
28. While rotating the pinion yoke back and forth, turn he right side differential adjuster nut sleeve clockwise using the J 36599-A until 0.0254-0.072 mm (0.001-0.003 inch) of backlash can be felt between the ring gear and the drive pinion. If the backlash specification cannot be obtained, turn the left side differential adjuster nut sleeve counter clockwise using the J 36599-A one notch at a time until the backlash specification can be obtained.
29. Using the J 36599-A turn the left side differential adjuster nut sleeve clockwise in order to preload the differential side bearings against the differential side bearings cups.
Tighten the differential adjuster nut to 75 Nm (55 lb ft).
30. Rotate the pinion several times in order to seat the pinion and differential side bearings.
31. Measure the rotating torque of the drive pinion and differential assembly using an inch-pound torque wrench.
The rotating torque of the pinion and differential assembly should be 0.57-1.13 Nm (5-10 lb in) greater than the rotating torque of the drive pinion measured earlier.
32. If the rotating torque of the drive pinion and differential assembly is not 0.57-1.13 Nm (5-10 lb in) greater than the rotating torque of the drive pinion, adjust the differential side bearing preload using the following steps:
1. Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides.
2. Using the J 36599-A , turn the left and right side differential adjuster sleeves in or clockwise one notch.
3. Using an inch pound torque wrench, measure the rotating torque of the pinion and differential assembly.
4. Compare the new measurement to the specification listed in Step 31. If the rotating torque of the pinion and differential assembly is not within specifications, continue to tighten the left and right side differential adjuster nut sleeves one notch on each side until the rotating torque of the pinion and differential assembly is within specifications.
33. If the rotating torque of the drive pinion and differential assembly is more than 1.13 Nm (10 lb in) above the rotating torque of the drive pinion measurement , adjust the differential side bearing preload using the following steps:
1. Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides.
2. Using the J 36599-A or the J 36615 , turn the left and right side differential adjuster nut sleeve out or clockwise one notch.
3. Using a torque wrench, measure the rotating torque of the pinion and differential assembly.
4. Compare the new measurement to the specification listed in Step 31. If the rotating torque of the pinion and differential assembly is not within specifications, continue to loosen the left and right side differential adjuster nut sleeve one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
34. Once the specified rotating is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.
35. Measure the drive pinion to the ring gear backlash and adjust, if necessary. Refer to Backlash Inspection and Adjustment (Backlash Inspection and Adjustment) .
36. Once the bearing preload and drive pinion to the ring gear backlash is within specifications, perform a gear tooth contact pattern check to ensure proper contact between the pinon and the ring gear. Refer to Gear Tooth Contact Pattern Inspection (Gear Tooth Contact Pattern Inspection) .
37. Complete the final assembly of the differential carrier. Refer to Differential Carrier Assembly Final Assembly (8.25 S4WD and 9.25 Lock Tab) (Differential Carrier Assembly Final Assembly (8.25 S4WD and 9.25 Lock Tab))Differential Carrier Assembly Final Assembly (8.25 F4WD Axle) (Differential Carrier Assembly Final Assembly (8.25 F4WD Axle)) .