Differential Case

Fig. 10 Assembling differential case:

Standard Differential
1. Place side gear thrust washer and side gear in differential case bore, Fig. 10. Liberally lubricate all differential components with suitable lubricant during assembly.
2. Using soft faced hammer, drive differential pinion shaft into case only far enough to retain pinion thrust washer and pinion gear.
3. Place second differential pinion and thrust washer in position and drive pinion shaft into place, carefully aligning pinion shaft lock pin holes.
4. Place second side gear and thrust washer in position and install pinion shaft lock pin and the cover on differential case then insert axle shaft spline in side gear spline to check for free rotation of differential gears.
5. Using suitable solvent, clean tapped holes in ring gear.
6. Insert two 7/16 N. F. bolts two inches long through differential case flange and thread them three or four turns into ring gear as a guide for aligning ring gear bolts, then press or tap ring gear into position. If new bolts show a green or yellow coating of at least 1/2 inch on threaded area, use as is. If bolts are not coated, apply small amount of suitable sealant to threads. Torque bolts to 70---80 ft. lbs. Never install used bolts.
7. If differential bearings were removed, press them on using tool T57L-4221-A2 or equivalent.
8. Wipe thin coating of suitable lubricant on carrier differential bearing bores, then place cups on bearings and set differential case assembly in carrier.
9. Assemble differential case and ring gear assembly in carrier so that marked tooth on drive pinion indexes between marked teeth on ring gear.
10. Slide assembly along bores until a slight amount of backlash is felt between gear teeth.
11. Set adjusting nuts in bores so that they just contact bearing cups, engaging nuts approximately the same number of threads on both sides.
12. Carefully position differential bearing caps on carrier, matching alignment marks.
13. Ensure that adjuster nuts are properly threaded in cap and carrier and that they turn freely, then install bearing caps and alternately torque them to 70---80 ft. lbs.
14. If adjusting nuts do not turn freely as cap bolts are tightened, remove differential bearing caps and inspect for damaged threads or incorrectly positioned caps.
15. Adjust backlash and differential bearing preload.

Traction-Lok Differential

When new clutch plates are used, soak plates in suitable hypoid lubricant for approximately 30 minutes before installation. Lubricate all parts with suitable hypoid lubricant during assembly.
1. Mount differential case in suitable vise and place side gear thrust washer and side gear in counterbore of case.
2. Install differential pinion thrust washers and place pinion gears on side gear, aligning holes in washers and gears with holes in case.
3. Install center block so that shaft holes are aligned with holes in pinion gears and case.
4. Using brass drift, drive in long differential pinion shaft from outside of case, aligning lock pin holes in shaft with lock pin holes in case.
5. Position center block so that long shaft is driven through rough side and short shaft is driven through machined side.
6. Using suitable drift, install shaft lock pins, ensuring that differential pinion and side gears move freely.
7. Place four preload pins in holes provided in center block.
8. Position preload plate over four springs, ensuring that springs are properly seated. The preload plate straddles the center block over its narrower machined width.
9. Mount differential cover in suitable vise.
10. Insert shims .050 inch total thickness, in cover cavity.
11. Install composite plate on back side of clutch hub with friction material against hub, then install, in order, a friction plate, steel plate, friction plate, steel plate, friction plate and steel plate.
12. Place clutch hub with clutch plates into clutch gear cavities in differential cover, ensuring that splines on last friction plate are engaged on hub.
13. Obtain locally a 5/8 inch by 2-1/2 inch or 9/16 inch by 2-1/2 inch bolt, nut, and two 1-1/2 inch O.D. flat washers approximately 1/8 inch in thickness. Install flat washer on bolt and place bolt through clutch hub. Hold bolt in place and turn cover over. Plate flat washer and bolt and install nut, torquing nut to 10---15 ft. lbs. while ensuring that washers remain centered.

Fig. 11 Shim pack thickness chart:

14. Place shim template tool in clutch hub. Some clearance should be observed between shim tool and cover to case mating surface. Determine exact amount of clearance using feeler gauge. The shim pack thickness chart, Fig. 11, will indicate correct amount of shims to subtract from .050 inch shims originally installed.
15. Remove bolt, nut and flat washers. Remove clutch hub and clutch plates as necessary to alter shim thickness.
16. Install selected shims in cover cavity, then reinstall components as described in steps 11 and 12.
17. Install four steel clutch ear guides and side gears.
18. Place both assemblies in press and press two halves together, then install two Allen head or Phillips head screws and tighten evenly until tight.
19. Install ring gear and ring gear bolts and washers. Torque bolts evenly and alternately across diameter of ring gear to 70---80 ft. lbs.
20. Using currently released locker tools, check torque required to rotate one side gear while other is held stationary. The initial breakaway torque may exceed 250 ft. lbs. The rotating torque required to keep the side gear turning with new clutch plates is 100---250 ft. lbs. With reused clutch plates, the minimum torque required is 40 ft. lbs. (Torque may fluctuate 10---40 ft. lbs.)