8.6 Inch, 9.75 Inch Axles

Locking Differential Assemble (8.6 Inch, 9.75 Inch Axles)

Important: The left and right side gear backlash and thrust block thickness measurement must be completed before the components of the locking differential can be assembled.

1. Measure the left and right side gear backlash and thrust block.





2. Install the locking differential clutch disc thrust washer into the left side or flange-end of the differential case.





3. Install the locking differential side gear cam unit and clutch disc assembly into the left side or flange-end of the differential case.
4. Install the differential side gear shim into the right side or bell-end of the differential case.





5. Install the differential side gear and clutch disc assembly into the right side or bell-end of the differential case.






Important: If the original pinion gears and thrust washers are being re-used, install the pinion gears and thrust washers on the same side as when removed.

6. Install the pinion gear and the pinion thrust washers.
Place the pinion gears and the pinion thrust washers 180 degrees apart.
7. Rotate the pinion gears and the pinion thrust washers 90 degrees and align the pinion gears with the pinion shaft opening in the differential case.





8. Install the thrust block.
The open side of the thrust block must face the window opening.





9. Install the pinion shaft.





10. Install the new pinion shaft lock bolt.

Tighten the pinion shaft lock bolt finger tight.





11. Install the governor assembly.





12. Install the latching bracket assembly.

The straight end of the latching bracket spring must be over and outside the governor assembly shaft.





13. Install the latching bracket bushing.
14. Install the governor assembly bushing.





15. Drive the governor bushing into position using a hammer and a brass drift.
Press the bushing into place until there is 0.025 - 0.076 mm (0.010 - 0.030 inch) of shaft end play.
16. Drive the latching bracket bushing into position using a hammer and a brass drift.

Press the bushing into place until there is 0.000 - 0.051 mm (0.000 - 0.002 inch) of shaft end play.
17. Tighten the pinion shaft lock bolt.
^ For the 8.6 inch axle, tighten the pinion shaft lock bolt to 36 Nm (27 ft. lbs.).
^ For the 9.75 inch axle, tighten the pinion shaft lock bolt to 27 Nm (20 ft. lbs.).

18. Install the ring gear.
19. Install the differential side bearings.
20. Install the differential assembly.