Assembly

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

1. Coat side gears with axle lubricant and install diaphragm springs with concave side toward gear, Fig. 8.

Fig. 9 Spreading side gears for pinion installation:

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

Fig. 11 Measuring side gear clearance:

2. Mount side gear assemblies in case, then center gears by inserting drive flanges. Side gear shims are not installed until side gear clearance has been measured.
3. Install side gear spreader assembly as shown in Fig. 9, then tighten bolt to spread side gears until gear can just be rotated with drive flange.
4. Coat differential pinions and pinion 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.
5. Remove spreader tool and drive flange, insert pinion shaft and secure shaft with lockpin. One end of pinion shaft hole is chamfered to ease installation of lockpin.
6. Position washer 331441 against face of side gear, thread bolt 33431 into washer from opposite side of gear, then tighten bolt until side gear is ``blocked'' against case, Fig. 10.
7. Mount a dial indicator on case with plunger bearing against face of blocked side gear, Fig. 11, then zero indicator.
8. Slowly loosen bolt clamping side gear, then record indicator reading and note position from which reading was taken.
9. Repeat steps 6 through 8 with remaining side gear, then disassemble differential assembly, keeping all components in order.
10. Select side gear shims to obtain clearance of .0008 to .0028 inch as follows:
a. Measure thickness of each diaphragm spring noting position and record measurement.
b. Add measured spring thickness to appropriate clearance measured during gauging procedure and record sum.
c. Obtain thickness of shim necessary to provide proper side gear clearance by subtracting desired clearance from sum obtained in previous step. Select shim to provide clearance as close to .0008 inch as possible.
11. Reassemble differential as outlined, installing selected shims in proper positions, then recheck clearance using procedure outlined in steps 6 though 8.
12. Install 2 guide pins in bolt holes on opposite sides of ring gear, heat ring gear to 212 degrees F, then mount gear on differential case.
13. Apply thread locking compound to new ring gear bolts, then remove guide pins and install ring gear bolts hand tight. Do not reuse ring gear bolts. Always use new bolts of the proper grade and dimension when installing ring gear.
14. Evenly tighten ring gear bolts in crossing pattern until torque of 36-40 ft. lbs. is obtained, then tighten each bolt an additional 50-60 degrees, maintaining crossing pattern during final tightening.
15. Press side bearings onto case and bearing races into bearing caps, ensuring bearings and races remain matched during assembly.
16. Ensure drive flange lock rings are properly positioned, with both ends of ring seated in groove, then press speed sensor spider onto differential case using spacer 331304 or equivalent.