Differential Carrier - Assembly

ASSEMBLY





1. Assemble the clutch pack as follows: Friction disc (1), tabbed plate (2), friction disc (3), tabbed plate (4), large friction disc (5), and Belleville spring (6). Verify the friction surface on the large friction disc (5) is facing the tabbed plate (4).






NOTE: Verify the raised edge of the Belleville spring (2) is facing up, or away from the clutch pack (1).

2. Install the clutch pack (1) and the Belleville spring (2) into the primary differential case half (3).





3. Install the differential side gear (1) into the primary differential case half (2).





4. Verify the differential side gear (1) is fully seated in the primary case half (2). Rotate the side gear as necessary to align the splines on all the friction plates with the splines on the differential side gear (1).





5. Install the secondary differential side gears (2), then slightly compress the Belleville spring by pressing down on the differential side gear, and install the secondary (split) pinion shafts (1).





6. Install the primary differential pinion gears (1).






NOTE: It may be necessary use the differential side gear to press downward on the four pinions (2) for primary differential pinion gear shaft (1) removal.

7. Install the primary differential pinion gear shaft (1).





8. Assemble the clutch pack as follows: Friction disc (1), tabbed plate (2), friction disc (3), tabbed plate (4), large friction disc (5), and Belleville spring (6). Verify the friction surface on the large friction disc (5) is facing the tabbed plate (4).






NOTE: Verify the raised edge of the Belleville spring (2) is facing up, or away from the clutch pack (1).

9. Install the clutch pack (1) and the Belleville spring (2).





10. Install the differential side gear (1).





11. Assemble the primary (1) and secondary (2) differential case halves.





12. Install the Ring Gear (2), and the Ring Gear Bolts (1). Tighten the ring gear bolts to 185 Nm (136 ft. lbs.).