Differential Carrier - Installation

INSTALLATION

Special Tools:










1. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth.

NOTE: Do not use water, steam, kerosene or gasoline for cleaning.

2. Lubricate differential case bearing.
3. Install differential case with bearings cups into the housing.

NOTE: A light coat of grease on the cups will hold them in place during installation.

4. Install bearing caps (2) and bolts. Tighten the bearing cap (2) bolts finger-tight.

NOTE: Do not torque bearing cap and bolts at this time.






5. 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.
6. Holding the differential case (2) toward the pinion gear, turn bearing adjusters with Adjuster Wrench (1) until they make contact with the differential bearings/cups.
7. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash.
8. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
9. Tighten pinion gear side adjuster firmly against the differential case bearing cup.
10. Rotate the pinion several times to seat the differential bearings.
11. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup.
12. Tighten pinion gear side adjuster until it just makes contact with the bearing cup.
13. Tighten pinion gear side adjuster an additional:
- New Bearings 6 Adjuster Holes
- Original Bearings 4 Adjuster Holes

14. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.





15. Tighten bearing cap bolts (4) to 281 Nm (207 ft. lbs.).
16. Tighten adjuster lock bolts (3) to 25 Nm (18 ft. lbs.).
17. Measure ring gear backlash and check gear tooth contact pattern. Refer to Adjustments for procedure.
18. Install axle shaft gasket and install axle shafts.
19. Install differential housing gasket and cover. Tighten cover bolts to 40 Nm (30 ft. lbs.).
20. Fill differential with lubricant to specifications.
21. Install fill plug and tighten to 32 Nm (24 ft. lbs.).