Assembly

Fig. 8 Side gear thrust washer & diaphragm spring installation. Exc. limited slip differential:

Fig. 9 Spreading side gears for pinion installation:

Fig. 6 Differential pinion shaft removal. Models w/standard differential:

Fig. 10 Blocking side gear for clearance check. Models w/standard differential:

Fig. 11 Measuring side gear clearance:

1. Ensure lock ring for pinion shaft is properly seated in groove.
2. Coat side gears with axle lubricant, then install diaphragm spring and shim on each gear with inside curved surface of spring facing gear, Fig. 8.
3. Mount side gear assemblies in case, then insert drive flanges to center gears.
4. Install spreader tool as shown in Fig. 9, then tighten bolt on tool until side gear can just be turned with drive flange.
5. Coat differential pinions and shaft with axle lubricant, position pinions opposite each other in mesh with side gears, then rotate drive flange to roll pinions into alignment with shaft bores in case.
6. When pinions are properly aligned, remove spreader tool, insert tapered mandrel through pinion and case bores, from direction ``E,'' Fig. 6.
7. Fit chamfered end of pinion shaft into mandrel, then press pinion shaft into position as follows:
a. If hydraulic press is used, monitor applied force carefully, and stop pressing when pressure reading increases, indicating that clip has engaged groove in shaft. Applying excessive force after clip engages groove in shaft will damage retaining clip. Do not push back on pinion shaft after engaging clip.
b. If press is not available, press shaft in by hand until 3/8 to 3/4 inch of shaft remains protruding from case.
c. Install puller tool No. 00 8 500 or equivalent, on case while forcing screw bearing on pinion shaft.
d. Torque forcing screw to 16 ft. lbs. Lubricate forcing screw prior to tightening, and ensure force is applied to pinion shaft in an even, progressive manner.
8. Position washer 331441 against face of side gear and thread bolt 331431 into washer from opposite side of gear, then tighten bolt hand tight, Fig. 10.
9. Mount a dial indicator on case with plunger bearing against face of side gear, Fig. 11, then zero indicator.
10. Tighten bolt to compress diaphragm spring, then record indicator reading.
11. Loosen bolt and rotate side gear, checking play as outlined at 3 evenly spaced positions.
12. Repeat steps 8 through 11 for remaining side gear, taking average 3 readings for each gear.
13. If average reading for each gear is not .0012 to .0040 inch, disassemble differential and replace side gear shims as needed, to obtain specified clearance. Select shims to provide clearance as close to .0012 inch as possible. After replacing shims, repeat clearance check to ensure proper adjustment.
14. Install guide pins in 2 opposite ring gear bolt holes, heat gear to 212 degrees F, then mount gear on case.
15. Apply locking compound to threads of new ring gear bolts, remove guide pins and install bolts hand tight. Do not reuse ring gear bolts. Always use new bolts of the proper grade and dimension when installing ring gear.
16. Torque ring gear bolts evenly in crossing pattern to 72-80 ft. lbs., then tighten each bolt an additional 50-55 degrees, maintaining crossing pattern during final tightening.
17. Press side bearings onto differential case and bearing races into bearing caps, ensuring bearings and races remain matched.
18. Ensure drive flange retaining rings are properly installed with both ends of ring fully seated in case groove.