Assembly
Assembly
1. Using the special tool, install the differential drive pinion bearing cup(s).
1 Position the bearing cup(s) on the special tool.
2 Position the special tool and the differential drive pinion bearing cup(s) in the differential housing.
3 Tighten the special tool to fully seat the differential drive pinion bearing cup(s) in the bore(s).
2. Using the special tools, install the differential front lower insulator.
Part 1:
Part 2:
3. NOTE: Install new drive pinion bearings without any additional lube since the anti-rust oil provided adequate lubricant without upsetting the drive pinion bearing preload settings.
Install the drive pinion bearings and special tools as shown.
4. NOTE: This step duplicates drive pinion bearing preload.
Thread the special tool onto the screw and tighten to the specification shown.
^ Tighten to 2.2 Nm (20 inch lbs.).
5. CAUTION: Position the adapter so it does not contact the housing.
CAUTION: Offset the special tool to obtain an accurate reading.
Rotate the special tool several half turns to seat the drive pinion bearings. Position the special tool as shown.
6. Install the special tool.
1 Position the special tool on the differential housing differential bearing seat.
2 Install the differential bearing caps.
3 Install the differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).
7. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the drive pinion bearing adjustment shim thickness between the gauge block and the gauge tube. A slight drag indicates correct shim selection.
^ Notice the plus (+), minus (-), or zero (0) paint marking on the drive pinion stem and adjust the thickness of the new shim. If the marking is plus (+), subtract the number from the gauged shim thickness. If the marking is minus (-), add the number to the gauged shim thickness.
8. Remove all of the special tools.
9. CAUTION: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly.
Position the drive pinion bearing adjustment shim and the inner pinion bearing on the drive pinion gear stem.
10. Using the special tools and a suitable press, firmly seat the drive pinion bearing adjustment shim and inner pinion bearing on the drive pinion gear stem.
11. CAUTION: Make sure the splines on the drive pinion gear stem are free of burrs. If burrs are evident, remove them using a fine crocus cloth.
Place a new differential drive pinion collapsible spacer on the drive pinion gear stem against the pinion stem shoulder.
12. Install the drive pinion gear with the differential drive pinion collapsible spacer in the differential housing.
13. Install the outer pinion bearing and the drive pinion oil seal slinger, drive pinion oil seal deflector.
14. CAUTION: Installation without the correct tool can result in early drive pinion seal failure.
CAUTION: If the drive pinion seal becomes misaligned during installation, remove it and install a new drive pinion seal.
NOTE: Coat the drive pinion seal lips with long-life grease.
Using the special tool, install the new drive pinion seal.
15. NOTE: Disregard the index marks if installing a new pinion flange.
Position the pinion flange.
1 Lubricate the pinion flange splines.
^ Use long-life grease.
2 Position the pinion flange.
16. Using the special tool, install the pinion flange.
17. CAUTION: Do not, under any circumstance, loosen the pinion nut to reduce drive pinion bearing preload. If it is necessary to reduce drive pinion bearing preload, install a new differential drive pinion collapsible spacer and pinion nut.
CAUTION: Remove the special tool while taking drive pinion bearing preload readings with the Nm (inch lbs.) torque wrench.
Use the special tool to hold the pinion flange while tightening the pinion nut.
^ Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (inch lbs.) torque wrench.
18. Tighten the pinion nut to set the drive pinion bearing preload. Refer to the torque specification for drive pinion bearings in the Specifications.
19. CAUTION: The master bearings are marked LH and RH. Install them as shown.
Install the special tools on the differential assembly.
20. CAUTION: Do not damage the aluminum differential housing while carrying out these procedures.
Place the differential assembly with the special tools in the differential housing.
21. Position the special tool on the outside mounting hole.
22. NOTE: Repeat this step until obtaining a consistent reading.
Measure the total end play.
1 Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
2 Move the differential assembly to the left and the right (as far as possible).
3 Record the reading on the differential bearing shim selection procedure line A.
Part 1:
Part 2:
Differential Bearing Shim Selection Chart
23. Remove the dial indicator and the differential assembly from the differential housing.
24. NOTE: If removed, press the speed sensor ring on with the differential ring gear.
Install the differential ring gear.
1 Place the differential ring gear on the differential assembly.
2 Hand start three ring gear bolts to align the holes in the differential ring gear and the differential assembly.
3 Place the differential assembly and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
4 Press the differential ring gear into place.
25. Install the remaining ring gear bolts.
^ Tighten to 105 Nm (77 ft. lbs.).
26. Place the differential assembly with the special tools into the differential housing.
27. NOTE: The ring gear bolts retaining the differential ring gear to the differential assembly may interfere while carrying out this procedure. If so, remove 3 to 5 ring gear bolts to provide clearance.
Measure the end play.
1 Attach the special tool and position the indicator tip on the machined surface of the differential assembly flange.
2 Rock the differential ring gear to allow full mesh with the drive pinion gear.
3 With the gears in full mesh, set the special tool to zero.
4 Move the differential assembly as far as possible to the left and note the reading.
5 Record the reading on the differential bearing shim selection procedure line B.
^ Remove the special tool.
28. Remove the differential assembly from the differential housing.
29. Remove the ring gear bolts. Apply stud and bearing mount to the ring gear bolt threads, and reinstall the ring gear bolts.
^ Use stud and bearing mount.
30. NOTE: Measure the stand height of both differential bearings prior to installation.
NOTE: Mark the differential bearings left and right before measuring them.
Install the special tool.
1 Place the special tool base in a soft jawed vise with the bearing mounting surface above the vise jaws.
2 Position the differential bearing on the special tool base.
3 Attach the bolt, spring, washers and spacer.
4 Tighten the bolt.
31. Measure the differential bearing stand height.
1 Invert the special tool and clamp the bolt head in a vise.
2 Position a depth micrometer flat on the differential bearing.
32. Measure both differential bearing's stand height. Record the measurement on the differential bearing shim selection procedure line D.
33. Press the left and right differential bearing on the differential assembly.
1 Position the appropriate differential bearing (LH or RH).
2 Using the special tool, press the differential bearing on the differential assembly.
34. Install the special tools.
35. CAUTION: Overspreading may damage the differential housing.
NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters prior to taking the final dial Indicator reading.
Spread the differential housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the screw until spreading the differential housing to the specification.
3 Remove the special tools.
36. CAUTION: To avoid galling the case, insert shims with a light coating of grease before installing the differential assembly. If not carried out in this order, aluminum housing can be damaged.
NOTE: Select the correct size differential bearing shims by completing the differential bearing shim selection chart.
Place the differential bearing shims in the differential housing.
^ Use long-life grease.
37. Install the differential assembly.
1 Position the differential bearing cups on the differential bearings.
2 Lower the differential assembly in place between the differential bearing shims.
38. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.
Install the differential bearing caps and the differential bearing cap bolts in their original locations and positions.
39. Remove the special tool.
40. Tighten the differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).
41. Install the special tool at the 12 o'clock position.
42. Using the special tools, measure the differential ring gear backlash at 4 equally spaced points.
1 Attach the special tool.
2 Position the special tool tip centrally on a drive tooth.
3 Zero the indicator.
4 Turn the differential ring gear without turning the drive pinion gear. Record the indicator reading. The allowable backlash is 0.254 mm (0.010 inch) to 0.305 mm (0.012 inch) and must not vary more than 0.101 mm (0.004 inch) between points measured. A backlash variation of more than 0.101 mm (0.004 inch) between points checked indicates gear/case runout.
If backlash is within specifications, install the differential assembly.
To correct for a high or low backlash, proceed as follows.
Part 1:
Part 2:
43. To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the following tables when adjusting the backlash. When the backlash is within specifications, install the differential assembly.
Part 1:
Part 2:
Differential Shim Size Chart-4067-
44. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.
CAUTION: Install the differential housing cover within 15 minutes of applying the silicone material.
CAUTION: Allow the sealant to cure for one hour before filling the axle with lubricant.
Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.
^ Use silicone gasket and sealant.
45. Install the differential housing cover.
46. Fill the axle assembly.
47. Install the rear axle assembly.