Electric Locking Differential Carrier - Installation
INSTALLATION
Special Tools:
1. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth.
2. Lubricate differential case bearing.
3. Install differential case with bearings cups into the housing.
4. Slide electric locker connector through differential housing.
5. Install o-ring (2) on electric locker connector.
6. Install electric locker connector retainer (1) and install connector with retainer in differential housing.
7. Install connector retainer bolt.
NOTE: Do not torque bearing cap and bolts at this time.
8. Install bearing caps (2) and tighten bearing cap bolts finger-tight.
9. Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained.
10. Holding the differential case toward the pinion gear, turn bearing adjusters with Adjuster Wrench until they make contact with the differential bearings/cups.
11. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash.
12. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
13. Tighten pinion gear side adjuster firmly against the differential case bearing cup.
14. Rotate the pinion several times to seat the differential bearings.
15. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup.
16. Tighten pinion gear side adjuster until it just makes contact with the bearing cup.
17. Tighten pinion gear side adjuster an additional:
- New Bearings: 6 Adjuster Holes
- Original Bearings: 4 Adjuster Holes
18. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
19. Tighten bearing cap bolts (4) to 165 Nm (122 ft. lbs.).
20. Tighten adjuster (2) lock bolts (3) to 25 Nm (18 ft. lbs.).
21. Measure ring gear backlash and check gear tooth contact pattern. Rear Axle - 10 1/2 AA
22. Install axle shafts.
23. Install sensor target magnet (1) on bearing cap.
24. Energize locker and rotate axle shaft. Verify dog clutch is engaged by rotating one axle while holding the other. If engaged axle will not rotate.
25. De-energize locker and rotate left axle 15 to 40 degrees so dog clutch gears will not engage.
NOTE: System will time out within 2 minutes when the key is in the on position and the engine is not running.
NOTE: If the axle is locking and the indicator light continues to flash, the sensor gap is too small. If the axle is disengaged and the indicator light stays on, the sensor gap is to large. Gap adjustment must be within spec.
26. Energize locker and set sensor air gap (2) to 5.5 mm ± 0.25 mm (0.21 in. ± 0.01 in.).
27. Tighten sensor target magnet bolt (3) to 7 Nm (62 in. lbs.).
NOTE: The next step will verify the sensor air gap was adjusted with the dog clutch gears ear to ear.
28. Hold right axle and rotate left axle until dog clutch engages with an audible click nose.
29. Install sensor wire tie strap (4) in the original location or at white dot on wiring harness to the top leg of adjuster lock and de-energize coil.
30. Install differential housing gasket and cover. Tighten cover bolts to 40 Nm (30 ft. lbs.).
31. Fill differential with lubricant to specifications.
32. Install fill plug and tighten to 32 Nm (24 ft. lbs.).