Final Assembly & Adjustment

1. Remove old differential bearing shims if not removed previously. Differential bearing preload is controlled by shims located between the differential case and bearings.
2. Install differential bearings. On model 30 and 44 axles, install bearings using driver handle J-7079-02 or equivalent, and installer J-22175 or equivalent. On model 60 axles, install bearings using driver handle and installer J-24430 or equivalent.
3. Install bearing cups on differential bearings, then differential in axle housing.
4. Install bearing caps and tighten cap bolts securely, but not to specified torque.
5. Hold ring gear in contact with pinion gear, then pry differential bearing cups toward center of case using a screwdriver.
6. Insert various thickness feeler gauges between each bearing cup and axle housing until ring gear backlash is 0.001-0.002 inch with feeler gauges installed. Feeler gauges must be installed on both sides of differential at the same time to obtain accurate measurement.
7. Assemble shim pack that will provide desired backlash. Check backlash again. If okay, tag and retain shims for assembly.
8. Remove differential case.
9. Add an additional 0.015 inch thickness shim to shim pack to be installed on tooth side of ring gear.
10. Remove differential bearings and install shim packs on appropriate sides of differential case, then reinstall differential bearings. On model 30 and 44 axles, install bearings using tools J-7079-02 and J-22175 or equivalents. On model 60 axles, install bearings using tool J-24430 or equivalent. When overhauling a front axle differential, check the axle housing inner oil seals. If seal replacement is required, install replacement seals using tool J-28648 or equivalent.
11. Mount spreader tool J-25102 and a dial indicator onto housing. Spread housing no more than 0.020 inch or damage could occur.
12. Remove dial indicator when housing has been spread to desired amount.
13. Lubricate differential bearings with suitable lubricant, then install differential bearing cups on bearings.
14. Install differential in housing using a rawhide mallet to seat differential. Be sure ring and pinion gear teeth mesh completely. Check ring gear and pinion tooth contact using suitable marking compound, and correct adjustment as needed to obtain even, centered contact.
15. Remove axle housing spreader tool. Apply sealing compound to bearing cap bolt threads. Torque bolts to 40 ft-lbs, on model 30 axles and 80 ft-lbs, on model 44 and 60 axles.
16. Remount dial indicator on housing and measure ring gear backlash. Measure backlash at two points. Backlash should be 0.005-0.010 inch. If backlash is incorrect, add or subtract shims from differential bearing shim packs until correct backlash is obtained. Changing position of a 0.005 inch shim from one side to the other, will change amount of backlash approximately 0.003 inch.
17. Measure ring gear runout. If runout exceeds 0.006 inch, case may be distorted, or there is dirt between case and gear, or ring gear bolts are loose. Check and correct as necessary.
18. Raise spring and install front spring shackle to spring. Torque to specifications.
19. Remove jackstand and install tie plate and U-bolts. Torque 1/2 inch bolts to 55 ft-lbs, and 9/16 inch bolts to 100 ft-lbs.
20. Install stabilizer bar link to tie plate attaching nut, then install shock. Torque shock to tie plate retaining nut to 45 ft-lbs.
21. Install axle shafts and axle housing cover. On model 44 and 60 axles, clean cover and mating surfaces. Apply a thin bead of RTV or equivalent, to housing and cover before installation.