M. Install Differential

NOTE:
Differential frame bracket reinforcement repair requires the use of P/N CAAP9982 repair package.

1. On vehicles that have not had the toe link replaced, remove the left outer toe link bolt and reinstall it so that the bolt enters from the back side of the toe link bracket. Tighten the bolt to 50 ft. lbs. (68 N.m). Failure to reverse the bolt installation orientation will trap the bolt if future toe link service is required.





2. On the left lower frame rail, measure 2-5/8 inches (67 mm) rearward from the rear edge of the frame locating hole and draw a line across the bottom of the frame (Figure 41).

3. Place the "Z" bracket on the frame as shown in Figure 41. Clamp the "Z" bracket into place.

CAUTION:
Do not over tighten the clamps.

4. Using the "Z" bracket as a template, drill two 14 inch (6.35 mm) holes in the top side of the lower frame rail (Figure 41).

5. Brush zinc rich primer into holes drilled in Step 4 to prevent corrosion.

6. Attach the "Z" bracket to the frame with two structural rivets using a power rivet gun (W-AK175ACH) or equivalent.

7. Remove the clamps from the "Z" bracket.

8. Using the "Z" bracket as a template, drill the remaining three 14 inch (6.35 mm) holes into the side of the frame (Figure 41).

9. Brush zinc rich primer into holes drilled in Step 8 to prevent corrosion.





10. Install three structural rivets using a power rivet gun (W-AK175ACH) or equivalent.

11. If removed, install the right and left axle shafts to the wheel flanges. Tighten the U-joint straps at the wheel flange to 27 ft. lbs. (36 N.m).

12. Place and secure the differential assembly on a transmission jack or equivalent.

13. Position the differential assembly into the vehicle.

14. Install the differential-to-pinion crossmember mounting bolts. Do not tighten the bolts at this time.

15. Install the differential mounting bolts at the differential cover isolator bushings. Do not tighten the bolts at this time.





16. Remove the left side differential mounting bolt and install the differential support bracket (Figure 42).

NOTE:
The differential support bracket wings may need to be spread slightly to aid in the installation.

17. Install the new left side differential mounting bolt provided. Do not tighten at this time (Figure 42).

18. Lightly clamp the differential support bracket to the frame rail (Figure 43).

CAUTION:
Do not over tighten the clamp.

19. Tighten the differential and pinion crossmember mounting bolts to 100 ft. lbs. (135 N.m).

20. Tighten the differential mounting bolts at the differential cover isolator bushings to 100 ft. lbs. (135 N.m).

21. Remove the transmission jack from under the differential assembly.

22. Remove the left rear shock absorber assembly.





23. Place a jack stand under the left rear lower control arm and raise the suspension to allow access to drill the in the frame (Figure 44).

24. Using the differential support bracket as a template, drill two 1/4 inch holes in the frame as shown in Figure 44.

25. Apply corrosion resistant primer into the holes made in Step 24.

26. Using the provided structural rivets, attach the differential support bracket to the frame rail using power rivet gun (W-AK175ACH) or equivalent.

27. Remove the clamp from the frame.





28. Using the "Z" bracket as a template, drill two 1/4 inch holes into the differential support bracket (Figure 45).

29. Apply corrosion resistant primer into the holes made in step 28.





30. Using the provided structural rivets, attach the "Z" bracket to the differential support bracket (Figure 45).

31. Apply black spray paint to all rivet heads.

32. Lower the jack stand and install the left shock absorber assembly. Do not tighten mounting bolts at this time.

33. With the jack stand under the left rear lower control arm, raise the lower control arm until full vehicle weight is on the suspension.

34. Tighten the lower shock absorber mounting bolt to 100 ft. lbs. (135 N.m).

35. Tighten the upper shock absorber mounting bolt to 100 ft. lbs. (135 N.m).

36. Remove the jack stand.

37. Install the driveshaft. Tighten the universal joint strap bolts to 320 in. lbs. (36 N.m).

38. Connect the right and left axle shafts to the differential flanges. Tighten the universal joint strap bolts to 320 in. lbs. (36 N.m).

39. If previously removed, install the stabilizer bar (Figure 46). Tighten the stabilizer bar isolator bushing retainer bolts to 50 ft. lbs. (68 N.m). Tighten the stabilizer bar attaching link nuts to 200 in. lbs. (23 N.m).





40. If previously removed, install the right and left toe links. While pulling down on the toe link, tighten the outer toe link bolt to 50 ft. lbs. (68 N.m). Then tighten the inner toe link mounting bolt to 50 ft. lbs. (68 N.m) (Figure 47).

CAUTION:
Be sure that the rear toe pattern adjustment shim is in its original position and that the left outer toe link mounting bolt is installed so that the bolt enters from the rear side of the toe link bracket.

41. If removed, install the toe link through the knuckle arm. Then install the castle nut. Tighten the castle nut to 38 ft. lbs. (52 N.m) and install the cotter pin.

42. Install the park brake cable retainer.

43. Install the rear exhaust pipes and muffler assembly (Figure 13).

44. Install the two rear exhaust isolators (Figure 13).

45. Install the center exhaust isolators.

46. Tighten the two rear exhaust clamps to 55 ft. lbs. (70 N.m).

47. If removed, place the battery onto the battery tray. Tighten the hold down bolt to 124 in. lbs. (14 N.m).

48. Connect and tighten the positive battery cable first. Then connect and tighten the negative battery cable.

49. Install the battery access panel.

50. If removed, install right wheel opening splash shield.





51. Install both rear wheel and tire assemblies onto vehicle. Tighten lug nuts to 90 ft. lbs. (122 N.m) and tighten in the order shown in Figure 48.

NOTE:
Wheel and tires are unidirectional. Verify that the correct wheel and tire assembly is on the correct side of the vehicle.

52. Lower vehicle from the hoist.

53. ^ If the vehicle had the steering gear crossmember or differential mounting bracket replaced, continue with Section "N - Wheel Alignment."

^ If the vehicles did not have the steering gear crossmember or differential mounting bracket replaced, wheel alignment is not required. Return the vehicle to the customer. No further action is necessary.