Part 2

Differential Bearings

Installation

1. CAUTION: Do not omit the drive pinion bearing oil baffle or drive pinion bearing failure may result.

If removed, position the drive pinion bearing oil baffle on the special tool.





2. Using the special tool, install the drive pinion bearing oil baffle.





3. Using the special tool, install the drive pinion bearing cups.





4. 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 or damage to the component may occur.

NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.

Assemble and position the special tools.








5. NOTE: This step duplicates final drive pinion bearing preload.

Tighten the special tool.
^ Tighten to 2.2 Nm (20 lb-inch).





6. NOTE: The special tool must be offset to obtain an accurate reading.

Rotate the special tool several half-turns to make sure of correct seating of the drive pinion bearings and position the special tool.





7. Install the special tool.
1. Position the special tool.
2. Install the 2 differential bearing caps.
3. Install the 4 differential bearing cap bolts.
^ Tighten to 105 Nm (77 lb-ft).





8. NOTE: Drive pinion bearing adjustment shims must be flat and clean.

NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in final assembly of integral axle assemblies.

Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
^ After the correct drive pinion bearing adjustment shim thickness has been determined, remove all of the special tools.





9. Position the drive pinion bearing adjustment shim and the inner pinion bearing on the drive pinion gear stem.





10. NOTE: The same drive pinion bearing from the previous steps must be used.

Install the inner drive pinion bearing.
^ Place the drive pinion bearing adjustment shim on the drive pinion gear.
^ Using a suitable press and the special tool, press the inner drive pinion bearing until it is firmly seated on the pinion gear.





11. Place a new drive pinion collapsible spacer on the drive pinion gear.





12. Install the outer drive pinion bearing.





13. Install the drive pinion oil slinger.





14. NOTE: Coat the drive pinion seal lips with long-life grease.

Install the drive pinion seal on the special tool.





15. NOTE: If the drive pinion seal becomes misaligned during installation, remove it and install a new drive pinion seal.

Using the special tool, install the drive pinion seal.





16. Lightly lubricate the drive pinion gear splines with rear axle lubricant.
17. Position the drive pinion gear in the axle housing.





18. Position the pinion flange.





19. Using the special tool, install the pinion flange.





20. Apply a small amount of axle lubricant to the washer side of the new pinion nut and install the new pinion nut.

21. CAUTION: Do not loosen the pinion nut to reduce drive pinion bearing preload under any circumstance. If it is necessary to reduce drive pinion bearing preload, install a new drive pinion collapsible spacer and pinion nut or damage to the component may occur.

Install the special tool and tighten the pinion nut. Refer to torque specifications.
^ Rotate the drive pinion gear occasionally to make sure the drive pinion bearings are seating correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (lb-inch) torque wrench.








22. Press the left and right differential bearing on the differential case.
1. Position the differential bearing.
2. Using the special tool, press the differential bearing on the differential case.
^ Repeat for the other side.





23. Install the differential carrier.
1. Position the 2 differential bearing cups on the differential bearings.
2. Lower the differential carrier in place.





24. Install a differential bearing shim of the thickness shown on the LH side of the differential bearing.





25. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.

Install the left bearing cap and loosely install the 2 bearing cap bolts.





26. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.

Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.





27. Install the right bearing cap and 2 bolts.
28. Tighten the 4 differential bearing cap bolts.
^ Tighten to 105 Nm (77 lb-ft).





29. Rotate the differential carrier to make sure it turns freely.





30. Install the special tool at the 12 o'clock position.





31. 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 0.203 mm (0.008 inch) to 0.305 mm (0.012 inch) and must not vary more than 0.101 mm (0.004 inch) between points measured.
^ To correct for a high or low backlash, proceed as follows.





32. 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.

Differential Shim Size Chart - 4067 (Part 1):

Differential Shim Size Chart - 4067 (Part 2):

Differential Shim Size Chart - 4067 (Part 3):

33. Remove the 4 differential bearing cap bolts.
^ Remove the differential carrier.





34. Measure the thickness of the selected right and left bearing shims.
35. To establish differential bearing preload, increase both the left and right differential bearing shim thickness by 0.203 mm (0.008 inch).
36. Install the special tools.





37. 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.





38. 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, the aluminum housing can be damaged.

Place the differential bearing shims in the differential housing.





39. Install the differential carrier.
1. Position the differential bearing cups on the differential bearings.
2. Lower the differential carrier in place between the differential bearing shims.





40. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the special tool.

Install the 2 differential bearing caps and the 4 differential bearing cap bolts in their original locations and positions.





41. Loosen and remove the special tool.





42. Tighten the 4 differential bearing cap bolts.
^ Tighten to 105 Nm (77 lb-ft).





43. Rotate the differential carrier to make sure it turns freely.





44. Install the special tool at the 12 o'clock position.





45. Using the special tools, recheck the ring gear backlash.





46. Apply marking compound and rotate the differential assembly 5 complete revolutions.





47. Verify an acceptable pattern check. For additional information, refer to Diagnosis and Testing. Testing and Inspection
48. Install a new circlip on the intermediate shaft ends.





49. Install the axle housing tube and the 4 bolts.
^ Tighten to 73 Nm (54 lb-ft).





50. Install a new stub shaft seal.
51. Insert the intermediate shaft and engage the circlip with the differential side gear.
52. Remove the axle assembly from the special tool and place it on the bench.

53. NOTE: 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.

NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.

NOTE: 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.





54. Install the differential housing cover and the 10 bolts.
^ Tighten to 32 Nm (24 lb-ft).
55. Fill the axle assembly with the specified type and amount of axle lubricant.
56. Install the front axle assembly.