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ASSEMBLY/INSTALLATION
(1)
L i b e r a l l y lubricate a l l t h e components
w i t h
gear l u b r i c a n t .
(2) Place the t h r u s t washers on the differential side
gears and position the gears i n the differential case
counterbores.
I f r e p l a c e m e n t d i f f e r e n t i a l s i d e g e a r s o r t h r u s t
w a s h e r s a r e b e i n g
u s e d , r e f e r
t o D i f f e r e n t i a l
S i d e G e a r C l e a r a n c e M e a s u r e m e n t
A n d A d j u s t -
m e n t .
(3) Position the t h r u s t washers o n the differential
p i n i o n gears and mesh the p i n i o n gears w i t h the side
gears. E n s u r e t h a t t h e p i n i o n g e a r s a r e e x a c t l y
180 d e g r e e s o p p o s i t e e a c h o t h e r .
(4) Rotate the differential side gears t o a l i g n t h e
p i n i o n gears and the t h r u s t washers w i t h the differ-
e n t i a l p i n i o n gear mate shaft bores i n the differential
case.
(5) T h e contact surfaces on the r i n g gear and on
t h e differential case flange m u s t be clean and w i t h -
o u t any b u r r s .
(6) Use a n " A r k a n s a s " stone to remove any sharp
areas from the chamfered edge on the inside diame-
t e r o f the r i n g gear (Fig. 24).
Fig. 24 Sharp Edge Removal
T h i s p r e c a u t i o n (above) i s v e r y i m p o r t a n t , b e -
c a u s e o t h e r w i s e , d u r i n g t h e i n s t a l l a t i o n o f t h e
r i n g g e a r o n t h e d i f f e r e n t i a l case flange, a s h a r p
e d g e c o u l d " s h a v e " m e t a l f r o m t h e flange a n d , i f
t h e m e t a l b e c o m e s i m b e d d e d b e t w e e n t h e d i f f e r -
e n t i a l case flange a n d t h e r i n g g e a r , c a u s e t h e
r i n g g e a r n o t t o " s e a t " c o r r e c t l y o n t h e
flange.
(7) Heat the r i n g gear w i t h a heat lamp or b y i m -
m e r s i n g i t i n a hot fluid (water or oil). The r i n g gear
t e m p e r a t u r e should not exceed 300°F (149°C). D o n o t
u s e a t o r c h .
(8) Position the differential case and the r i n g gear
between the brass jaws of a vise and use pilot studs
(equally
spaced at three
locations)
to a l i g n t h e
PILOT STUD
FLANGE
PILOT STUDS
Fig. 25 Differential Case-To-Heated Ring Gear
Alignment
heated r i n g gear w i t h the differential case (Fig. 25).
(9) Insert replacement
r i n g gear bolts ( w i t h left
h a n d threads) t h r o u g h t h e differential case
flange
and thread t h e m into t h e r i n g gear.
A l t e r n a t e l y
t i g h t e n each bolt w i t h 95 N*m (70 ft-lbs) torque.
CAUTION: When installing a differential bearing,
never apply force to the bearing cage because bear-
ing damage will result.
(10) Place a differential bearing on each differen-
t i a l case hub (bearing taper facing away f r o m t h e
r i n g gear) and carefully "seat" the bearings o n t h e
hubs. For differential cases w i t h 8 3/8-inch diameter
r i n g gears, use Bearing I n s t a l l a t i o n Tool C-4340 and
D r i v e r Handle Tool C-4171. F o r differential cases
w i t h 9 1/4-inch diameter r i n g gears, use B e a r i n g I n -
stallation Tool C-4213 and D r i v e r Handle Tool C-
4171. A n arbor
press should be used
w i t h t h e
installation Tools (Fig. 26).
(11) Select the correct drive p i n i o n gear shaft gear
adjustment gauge set (Figs. 27 and 28) and continue
the assembly according to the following instructions:
• insert both drive p i n i o n gear shaft bearing cups
i n t o the differential housing bores (ensure t h a t they
are not cocked);
• for 8 3/8-inch diameter r i n g gear axles, position
Locating Spacer Tool SP-6030 over the shaft o f Tool
SP-5385 and follow i t w i t h t h e drive p i n i o n gear
shaft rear bearing; and
• position the tools ( w i t h the bearing) i n the differ-
e n t i a l housing, i n s t a l l Shaft Locating Sleeve Tool SP-
5382,
i n s t a l l t h e drive
p i n i o n gear
shaft
front
bearing, i n s t a l l Washer Tool SP-6022 followed b y
Compression Sleeve Tool SP-3194-B, and i n s t a l l Cen-
t r a l i z i n g - Washer Tool SP-534 followed b y Compres-
sion N u t Tool SP-3193.
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