Assembly

1. Place ring gear in oil bath heated to 212°F, then clean differential case to ring gear contact surface with suitable solvent. Do not heat ring gear to more than 230°F.
2. Align ring gear and differential case alignment marks, then install ring gear on case.
3. Install ring gear attaching bolts and lock plates, then torque ring gear attaching bolts to 71 ft. lbs. Bend over lock plates.
4. Press on side bearings using press and tools 09316-60010 and 09608-30012.
5. Install differential case into carrier and tighten adjusting nut until all play is removed, then check ring gear runout. Maximum runout is .004 inch. Remove differential.
6. Press in pinion front and rear bearing outer races using tools 09608-35014.
7. Install washer on drive pinion with chamfer end facing pinion gear.
8. Install new rear bearing onto drive pinion, using press and tool No. 09506-30012.
9. Temporarily adjust drive pinion preload as follows:
a. Install drive pinion and front bearing.
b. Install companion flange using tool No. 09557-22022.
c. Retain companion flange using tool No. 09330-0021, then adjust drive pinion preload to 8.7-13.9 inch lbs. for new bearings or 4.3-6.9 inch lbs. for used bearings.
10. Place bearing outer races on their respective bearings, then insert differential case into carrier.
11. Install shim on ring gear side of case side bearing, then ensure ring gear has backlash.
12. Tap on ring gear, using a suitable mallet to snug down washer and bearing, then retain side bearing boss on tooth surface and measure backlash. Backlash should be .0039 inch.
13. Select proper ring gear side of case side bearing shim, using backlash as reference.
14. Select ring gear side of case side bearing shim with a thickness that will eliminate clearance between outer race and carrier.
15. Remove shims and differential case, then install shim into lower part of carrier.
16. Place second shim onto differential case with outer races, then insert differential case, shim and outer races into carrier.
17. Snug down shim and bearing, by tapping on ring gear, using a suitable mallet.
18. Measure ring gear backlash, using a suitable dial indicator. Backlash should be .0051-.0071 inch. If backlash is not as specified, adjust number of shims on both sides an equal amount.
19. Adjust side bearing preload as follows:
a. Remove ring gear side of case side bearing shim, then measure and record thickness.
b. Install a new shim approximately .0024-.0035 inch thicker.

Fig. 32 Side Gear Bearing Shim Selection Chart. Supra:

20. Measure ring gear backlash, using a suitable dial indicator. Backlash should be .0051-.0071 inch. If backlash is not as specified, adjust number of shims on both sides an equal amount. Refer to Fig. 32, for shim sizes available.
21. Align reference marks on cap and carrier, then install side bearing caps and torque evenly to 58 ft. lbs.
22. Measure total preload with inch lbs. wrench on pinion nut. Preload should be 3.5-5.2 inch lbs. in addition to drive pinion preload.
23. Paint 3 or 4 ring gear teeth at 3 different positions on ring gear with red lead paint, then hold companion flange firmly and rotate ring gear in either direction.

Fig. 9 Ring Gear & Pinion Tooth Contact Inspection:

Fig. 33 Drive Pinion Shim Identification Chart. Supra:

24. Inspect gear tooth contact as shown, Fig. 9. If contacting pattern is not correct, select a suitable shim from chart, Fig. 33, that will ensure proper contact.
25. Remove companion flange and front bearing.
26. Install new bearing spacer and front bearing.
27. Install oil slinger, then drive in new oil seal to a depth of .059 inch.
28. Install companion flange, using tool No. 09557-22022, then apply a suitable lubricant to new nut. Retain companion flange, using tool No. 09330-00021, then install nut and torque to 134 ft. lbs.
29. Check preload of backlash between ring and pinion (measure pinion preload). Preload should be 8.7-13.9 inch lbs. on new bearings or 4.3-6.9 inch lbs. on used bearings.
30. If preload is greater than specified, replace bearing spacer. If preload is less that specified, torque nut 9 ft. lbs. at a time until specified preload is obtained. If a maximum torque to 250 ft. lbs. is exceeded during tightening procedure, replace bearing spacer and repeat preload adjustment.
31. Check companion flange runout. Runout in any direction should not exceed .004 inch. If runout exceeds specifications, inspect pinion bearing.
32. Stake drive pinion nut.
33. Apply a suitable lubricant to new side gear shaft oil seal, then drive in new oil seal using tool Nos. 09608-10010 and 09608-35014, until flush with carrier end surface.
34. Install new snap ring on side gear shaft, then using tool 09520-24010, drive in side gear shaft until it contacts pinion shaft.
35. Check side gear shaft runout. If runout exceeds .008 inch in either direction, replace side gear shaft.
36. Install differential carrier cover. Torque attaching bolts to 34 ft. lbs.