Installation

1. Slide the axle shafts into place in the axle housing. Exercise care so that the splines or any portion of the axle shafts do not damage the oil seals. Push the shafts inboard (toward the center of the vehicle) enough to allow installation of the C-lock.

Side Gear Removal:

Install the axle shaft C-locks on the button end of the axle shafts and push the shafts outboard so that the shaft lock seats in the counterbore of the differential side gear.

NOTE: A rubber 0-ring is used to hold the C-lock in position on the axle shaft. Be sure that the 0-ring is in the groove at the button end of the axle shaft before installing the C-lock.

Pinion Shaft And Lock Bolt Installation:

2. Position the differential pinion shaft through the case and pinions, aligning the hole in the shaft with the lock bolt hole. Apply Loctite (EOAZ-19554-B or equivalent) to the lock bolt threads. Install lock bolt and tighten to 20-40 Nm (15-30 ft-lbs).

3. Clean the gasket mating surface of the rear axle carrier casting and cover.

Differential Cover Sealing Procedure:

Apply a new continuous bead of silicone rubber sealant (D6AZ-1 9562-AA or -BA or equivalent) to the carrier casting face inside the cover bolt holes.

CAUTION: Make sure machined surfaces on both cover and carrier are clean and free of oil before installing the new silicone sealant. Inside of axle must be covered when cleaning the machined surface to prevent contamination.

Differential Cover Bolt Installation:

4. Install cover and tighten cover bolts to 34-47 Nn (25-35 ft-lbs) as shown. Tighten the cover bolts in a cross-wise pattern to insure uniform draw on cover. Tighten the ratio tag hold-down bolt to 20-34 Nm (15-25 ft-lbs).

NOTE: Cover assembly must be installed within 15 minutes of application of the silicone or new sealant must be applied.

Filler Plug Installation:

5. For in-vehicle repairs, add lubricant through the filler hole until the lubricant level reaches the bottom of the filler hole with the axle in the running position (approximately 6.5 U.S. pints). For out-of-vehicle repairs, add 7.5 U.S. pints of lubricant. Use Hypoid Gear Lubricant E0AZ-19580-A (ESP-M2C154-A) or equivalent for conventional axles, plus 8 ounces of C8AZ-19B546-A (EST-M2C118-A) or equivalent friction modifier for complete refill of Limited- Slip Applications.

Lower vehicle and road test.