Front Differential Case Assemble

Front Differential Case Assemble

Special Tools

* J 8092 - Universal Driver Handle - 3/4 in - 10

* J 8107-2 - Side Bearing Puller Pilot

* J 22888-D - Side Bearing Remover Kit

* J 33790 - Differential Side Bearing Installer

1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations Fluids.




2. Install the differential side gear thrust washers to the differential side gears.

3. Install the differential side gears and thrust washers into the differential case.
If the same differential side gears and the thrust washers are being used, install the side gears and the thrust washers to their original locations.

4. Install the differential pinion gears and thrust washers by performing the following steps:

1. Position one pinion gear between the differential side gears.

2. Position the second pinion gear between the differential side gear directly opposite of the first gear.

3. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case.

4. Install the thrust washers.
Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers.

5. Install the pinion gear shaft.

6. Install the new pinion gear shaft lock pin using a hammer and a brass drift.





Note: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

7. Install the ring gear onto the differential case.

Note: The ring gear bolts have left-hand threads.

8. Install the new ring gear bolts.
Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

Caution: Refer to Fastener Caution Fastener Caution.

9. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case and tighten to 84 Nm (67 lb ft).




10. Install the differential side bearings by performing the following steps:

1. In order to protect the differential case, install the J 8107-2 - Side Bearing Puller Pilot in the case on the side opposite the bearing installation.

2. Install the J 33790 - Differential Side Bearing Installer (2) and the J 8092 - Universal Driver Handle - 3/4 in - 10 (1) onto the differential case bearing as shown.

3. Install the differential case bearings using the J 33790 - Differential Side Bearing Installer and the J 8092 - Universal Driver Handle - 3/4 in - 10.