Assembly

1. Install the clutch packs, side gears and thrust washers. To do this, whether the original plates and discs or new ones are used, assemble them in exactly the same order as the originals. Always replace the entire kit of plates and discs even if only one component requires it. Refer back to illustrations used during disassembly for guidance in subsequent re-assembly operations.

2. Prelubricate the thrust face of the side gear and assemble the plates and discs to the side gear splines, prelubricating each part with Hypoid Gear Lubricant C6AZ-1 9580-A (ESW-M2C105-A) or equivalent or with Additive Friction Modifier C8AZ-19B546-A (EST-M2C118-A) or equivalent friction modifier lubricant, both stacks.

CAUTION: If the discs are of the newer coated design (without concentric grooves), It is important to soak them for twenty minutes in Additive Friction Modifier C8AZ-19B546-A (EST-M2C118-A) before assembly.

3. Assemble the retainer clips to the ears of the plates. Make sure both clips are completely assembled or seated onto the ears of the plates.

With the differential case positioned as shown, assemble the clutch pack and side gear into the case. Make sure the clutch pack stays assembled to the side gear splines, and that the retainer clips are completely seated into the pockets of the case. To prevent the pack from falling out of the case, hold them in place by hand while re-positioning the case on a bench.

4. Re-position the case on the bench and assemble the step plate into the side gear. Apply a small amount of grease, Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or equivalent into the centering hole of the step plate.

5. Assemble the other clutch pack and side gear. Make sure the clutch pack stays assembled to the side gear splines, and that the retainer clips are completely seated into the pockets of the case. Install Step Plate, T83T-4205-A4 or equivalent, on top of the side gear.

6. Hold the side gear in position by hand. Insert the Forcing Screw T83T-4205-A3 down through the top of the case, and thread Forcing Nut, T83T-4205-A2, on the screw. The tip of the Forcing Screw must contact the Step Plate.

7. With tools assembled to the case, position the case onto the axle shaft (as a holding fixture) by aligning the splines of the side gear with those of the shaft.

8. Position both differential pinion gears opposite one another through the openings in the case. Be sure the holes of the gears are lined up with each other. Hold the gears in place by hand.

Tighten the forcing screw so that the side gears will move away from the differential pinion gears and relieve the loaded condition.

9. While holding the differential pinion gears in place, insert the Handle (T83T-4205-A1 or equivalent) into the pinion mate shaft. Pull on the handle so that the case will rotate and allow the differential pinion gears to rotate and enter into the case.

As mentioned under Disassembly, it will probably be necessary to adjust the forcing screw by very slightly loosening or tightening it until the required load is applied to allow the side gear and differential pinion gears to rotate.

10. Rotate the case until the holes of both differential pinion gears are lined up exactly with those of the case.

Prelubricate both sides of the pinion spherical washers with the specified lubricant, Hypoid Gear Lubricant C6AZ-19580-E (ESW-M2C105-A) or equivalent.

11. Apply torque to the forcing screw to allow clearance to assemble the spherical washers.

CAUTION: Do not overtighten the forcing screw. Overtightening the forcing screw may clamage the clutch plate and disc assemblies.

Assemble washers into the case. Use a very small screwdriver to push the washers into place. Be sure the holes of the washers and gears are lined up exactly with those of the case. Remove the forcing screw, forcing nut, handle, and step plate.

Install the pinion shaft in the differential case. install the cross shaft locking pin.

12. Install the ring gear on the differential case, and tighten the attaching bolts to specification. Refer to Specifications in Integral Carrier Axle-Dana.