Assembly

Axle






























Assembly

Assembly, differential case and ring gear - Traction-Lok(R)

1. Prelubricate each steel clutch plate and soak all friction plates with 118 ml (4 oz) of friction modifier for at least 15 minutes.





2. NOTE: The concave side of the Belleville spring must face up and against the thrust face of the differential case.

Place the shim and the Belleville spring on the differential clutch pack.





3. Insert the differential clutch packs with the shims and Belleville springs and differential side gears into the differential case.





4. NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.

Assemble the Differential Gauge in the differential case.

1. Position the Differential Gauge in the bottom side gear bore.

2. Position the Differential Gauge in the top side gear bore and hold it in place.

3. Install the Differential Gauge and tighten it 2 turns after it contacts the bottom step plate.





5. NOTE: Coat both sides of the differential pinion thrust washers with rear axle lubricant.

Position the differential pinion gears and thrust washers in the differential case window so they mesh with the differential side gear teeth.





6. NOTE: It may be necessary to loosen or tighten the Differential Gauge forcing screw to allow the differential side gears to rotate.

Insert the Differential Gauge into the pinion shaft bore and turn the differential case. This will move the differential side gears and position them in the differential case. Rotate the differential case until the pinion mating shaft holes are aligned with the differential pinion gears.





7. Loosen the Differential Gauge forcing screw and remove the Differential Gauge from the differential case. Install a new differential pinion shaft and bolt in the differential case.





8. If removed, install new differential carrier bearings.





9. Using the Differential Gauge, check the torque required to rotate on differential side gear.
- Install the Differential Gauge as shown.

- If the original clutch plates are used, the initial breakaway torque must be within specification. The rotating torque required to turn the differential side gear with new clutch plates, may vary.





10. Install the differential ring gear.

1. Place the differential ring gear on the differential case.

2. Hand-start 3 new bolts to align the ring gear to the differential case.

3. Place the differential case and ring gear on the press bed with the ring gear teeth facing down.

4. Press the ring gear into place on the differential case.





11. Install the 9 remaining new ring gear bolts.
- Tighten alternately and evenly to 150 Nm (111 lb-ft).





Assembly, differential case and ring gear - conventional

12. NOTE: Coat the differential side gears and differential side gear thrust washers with rear axle lubricant.

Position the differential thrust washers on the differential side gears.





13. Position the differential side gears and thrust washers in the differential case.





14. NOTE: Coat the differential pinion thrust washers and differential pinion gears with rear axle lubricant.

Assemble the differential pinion thrust washers and the differential pinion gears.





15. Engage the differential pinion gears opposite the differential side gears.





16. Rotate the differential pinion gears to align with the differential pinion shaft bore.





17. Insert the differential pinion shaft.





18. Install a new differential shaft lock bolt.
- Tighten to 30 Nm (22 lb-ft).





19. Using the Differential Carrier Bearing Installer, install the differential bearings.





20. Install the differential ring gear.

1. Place the differential ring gear on the differential case.

2. Hand-start 3 bolts to align the holes in the differential ring gear and the differential case.

3. Place the differential case and the differential ring gear on the press bed with the ring gear facing down.

4. Press the ring gear into place.





21. Install the 9 remaining new differential ring gear bolts.
- Tighten alternately and evenly to 150 Nm (111 lb-ft).





Final assembly - all differentials

22. Position the inner and outer bearing cups in their respective bores.

1. After positioning the bearing cups in the bores, place the Rear Axle Pinion Bearing Cup Installer on the inner bearing cup.

2. Place the Rear Axle Pinion Bearing Cup Installer on the outer bearing cup.

3. Install the Drive Pinion Bearing Cup Installer.





23. Tighten the Drive Pinion Bearing Cup Installer to seat the bearing cups in the bores.





24. NOTE: If a feeler gauge of the specification shown can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.

Make sure the differential pinion bearing cups are correctly seated.





25. NOTE: Apply a light film of axle lubricant on the front and rear pinion bearings.

Install the pinion bearings and Drive Pinion Depth Gauge/Aligner, Drive Pinion Gauge Tube, Drive Pinion Depth Gauge/Aligner and Adapters as shown.









26. NOTE: This step duplicates pinion bearing preload.

Tighten the Adapter to the specified rotational torque.

- Tighten to 2.2 Nm (20 lb-in) rotational torque.





27. NOTE: Position the Adapter so it does not contact the housing.

NOTE: Offset the Adapter to obtain an accurate reading.

Rotate the Adapter several half turns to seat the drive pinion bearings and position the Adapter as shown.





28. Install the Drive Pinion Gauge Tube, 2 bearing caps and 4 bolts.
- Tighten to 105 Nm (77 lb-ft).





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

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

Use a drive pinion bearing adjustment shim as a gauge for shim selection.





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





31. Using the Bearing/Oil Seal Plate and Drive Pinion Bearing Installer, press the inner pinion bearing and pinion shim until they are firmly seated on the pinion.





32. NOTE: 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 drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder.





33. Install the outer pinion bearing and the drive pinion oil seal slinger.





34. NOTICE: Installation without the correct tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one.

NOTE: Coat the lips of the rear axle drive pinion seal with grease.

Place the drive pinion oil seal on the Drive Pinion Oil Seal Installer and drive the seal into place.





35. NOTE: Lubricate the pinion flange splines with rear axle lubricant.

Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing. Seat the drive pinion with a plastic hammer.





36. NOTE: Disregard the scribe marks if a new pinion flange is being installed.

Align the pinion flange with the drive pinion shaft.





37. With the drive pinion in the axle housing, install the pinion flange using the Drive Pinion Flange Installer.





38. Position the new pinion nut.





39. NOTICE: 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 or damage to the component may occur.

NOTE: Remove the Drive Pinion Flange Holding Fixture while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench.

Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten 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 (lb-in) torque wrench.





40. Tighten the pinion nut to set the drive pinion bearing preload. Refer to the torque specification for drive pinion bearings in the Specifications information.





41. With the pinion depth set and the pinion installed, place the differential case in the rear axle housing.

42. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.

Install a shim as shown on the left side.





43. NOTE: Apply pressure toward the left side to make sure the left bearing cup is seated.

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





44. Install progressively larger shims on the right side until the largest shim selected can be installed by hand.





45. Install the right side bearing cap and tighten the 2 bolts.
- Tighten to 105 Nm (77 lb-ft).





46. Rotate the differential case to make sure it rotates freely.





47. Adjust the ring gear backlash. For additional information, refer to Ring Gear Backlash Adjustment Adjustments.

48. Install the rear axle assembly. For additional information, refer to Axle Assembly Axle Assembly.