Differential Case Assembly

Part 1 Of 2:

Part 2 Of 2:

INSTALL OR CONNECT

NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you Install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

- Tools Required:
- J 8107-3 Differential Side Bearing Removal Plug
- J 8092 Driver Handle
- J 29710 Differential Side Bearing Installer

1. Lubricate all parts with axle lubricant.
2. Side gear thrust washers to the side gears.
3. Side gears to the differential case.
- Install the side gears on the same side as when removed.
4. Pinion gears to the differential without the pinion thrust washers.
A. Install the pinion gears onto the side gears so the holes in the pinion gears are 180° apart.
B. Rotate the pinion gears into place, and verify the pinion gears line up with the pinion shaft holes.
5. Pinion thrust washers.
- Rotate the pinion gears toward the differential opening enough to slide in the pinion thrust washers.
- Make sure the mating surfaces of the differential case and ring gear are clean and burr free.
6. Ring gear to the differential case.
A. Thread two left-hand threaded bolts into the ring gear on opposite sides.





B. Place the ring gear onto the case, and align the holes in the case with the bolts.





C. Press the ring gear onto the case far enough to start the bolts using J 8107-3 to protect the differential from the press ram.
7. Ring gear bolts.
- Tighten the ring gear bolts alternately, and in stages gradually pulling the ring gear onto the differential case.
- Tighten bolts to 145 Nm (105 ft. lbs.).





8. Differential side bearings using J 29710, J 8107-3, and J 8092.
- Place J 8107-3 into the differential on the side opposite the bearing installation to protect the differential case.
- Drive the bearing onto the case using J 29710 and J 8092.
9. Differential case to the axle housing. Refer to SIDE BEARING PRELOAD ADJUSTMENT.