Assembly
ASSEMBLYDIFFERENTIAL/RING GEAR ASSEMBLY
1. Install pinion shaft (1), pinion gears (3) and thrust washers (2) as shown.
2. Using suitable punch, install new roll pin and install flush to differential case (1).
3. Install differential side gears and thrust washers (1,2). Rotate into position.
4. Using Tool 9666 (1), install new differential side bearing (ring gear side).
5. Using Tool 9665 (1), install new differential side bearing (opposite side).
PINION HOUSING ASSEMBLY
1. Using Tools C-4171 (2) and D-129 (1), press new pinion head bearing cup (3) into pinion gear housing.
2. Using Tools C-4171 (1) and D-130 (2), press new pinion tail bearing cup into pinion gear housing.
3. Using Tool L-4507, install new pinion head bearing.
4. Install pinion bearing select spacer (1) removed upon disassembly. Spacer thickness will be measured/verified at end of assembly.
5. Install pinion gear/bearing assembly into pinion housing. Using Tool L-4507 (1) , press new pinion tail bearing (2) onto shaft.
6. Using Tool 9677 (1), install new pinion seal.
7. Using Tool L-4507 (1), install pinion flange (2) until it bottoms.
8. Using Tool 6958 (2), install pinion flange nut and torque to 475 Nm (350 ft. lbs.).
9. Measure pinion housing assembly rotating torque (1). Rotating torque should be within 130 - 260 Nm (12 - 23 inch lbs.).
10. If rotating torque is lower than this range, disassemble pinion housing, measure and install a slightly thicker spacer (1), reassemble and reverify. If rotating torque is higher than this range, disassemble pinion housing, install a slightly thinner spacer, reassemble and reverify rotating torque.
AXLE HOUSING ASSEMBLY
1. Using Tool L-4507, install new axle seal (inner) into housing.
2. Install side bearing preload shim into axle housing.
3. Using Tools C-4171 and D-145, press new side bearing cup into housing until it bottoms.
4. Install differential side bearing preload shim (1) into axle housing cover (2).
5. Using Tools C-4171 and D-129 (1), press new side bearing cup into cover until it bottoms. Use suitable cup (3) to support and protect cover.
6. Install differential/ring gear assembly (3), new cover O-ring seal (4), and cover (5).
7. Install and torque cover-to-housing bolts to:
^ M10 x 40 - 65 Nm (48 ft. lbs.)
^ M8x25 - 34 Nm (25 ft. lbs.)
8. Using Tool C-4995 (1), measure differential side bearing rotating torque (preload). Rotating torque should be within 190 - 260 Nm (17 - 23 inch lbs.).
9. If rotating torque is below this range, disassemble housing, measure and install slightly thicker preload shims (1). Add thickness equally to both sides. If rotating torque is above this range, disassemble housing, measure and install slightly thinner preload shims. Remove thickness equally from both sides.
10. Install new pinion housing O-ring seal (1).
11. Install pinion housing assembly into axle housing with proper pinion depth shim (1).
12. Install and torque pinion housing-to-axle housing bolts (1) to 34 Nm (25 ft. lbs.).
13. Measure and adjust ring gear backlash. Backlash should be within 0.05 - 0.11 mm (0.002 - 0.004 inch).