Differential Carrier - Assembly

ASSEMBLY

Special Tools:










1. Lubricate all differential components with hypoid gear lubricant.
2. Install differential side gears (2) and thrust washers to Fixtures (1) as shown in illustration.





3. Install differential pinion gears (1) and thrust washers into position across from each other.





4. Rotate pinion gears into place using Fixture and line up gear centers with pinion shaft bore.





5. Using a brass hammer, drive pinion shaft (3) into differential case (1), making sure to line up roll pin bores.
6. Using suitable punch (2), drive new roll pin into position.





7. Measure differential gear rotating torque as shown. Differential gear rotating torque should be 5-30 Nm (44-266 in. lbs.) Rotating torque is adjusted using select side gear thrust washers. Refer to the following chart.









8. Remove differential case from Mounting Plate (2).





9. Install ring gear to case. Lightly tap ring gear into position to facilitate starting of bolts.
10. Install new ring gear-to-case bolts and torque to 85 Nm (63 ft. lbs.).





11. Using Installer (2) and Handle (1), press new differential side bearings (3) onto differential case.