Front Differential Case Assemble (With E-Locker)

Front Differential Case Assemble (With E-Locker)

Special Tools
* J 7872 - Magnetic Base Dial Indicator
* J 8001 - Dial Indicator Set
* J 8092 - Universal Drive Handle
* J 25299 - Side Bearing Installer

Assembly Procedure




1. Install the shim (2) side gear (1) differential case (3).




2. Install the thrust washers (1), side gears (2), and the pinion shaft (4) in the differential case (3).




3. Using a hammer, install the roll pin for the pinion shaft.




4. Install the J 8001 - dial indicator set (1) on the differential case (2).
5. Position the dial indicator (1) so that it is on the tooth of the spider gear.
6. Rotate the side gear back and forth and record the reading 0.004 in to 0.006 in.
7. If the reading is with specification, proceed to the next step. If not, replace the shims and recheck the reading.




8. Install the electronic locking differential plate (3), locking side gear (2), and the shim (1) in the differential carrier case (4).




9. Install the front differential preload spring (1) in the differential carrier case (2).





Note: It may be necessary to use a screwdriver or punch as an alignment guide when assembling the differential carrier case halves.

10. Using a dead blow hammer, lightly tap the differential case halves (1) and (2) until they are seated.





Caution: Refer to Fastener Caution (Fastener Caution).

11. Install the screws (1) for the differential case (2) and tighten to 9 Nm (80 lb in).





Note: When installing the differential case in the vise, ensure that the opening on the side of the differential case is facing up so that access to the spider gears.

12. Install the differential case (4) in a soft jawed vise.
13. Insert a flat bladed tool such as a chisel or screw driver (1) in the access hole in the differential case to hold the side gear in place.
14. Install the J 7872 - magnetic base dial indicator (2) on the differential case (4).
15. Position the dial indicator (3) on the side gear.
16. Applying slight pressure to the bladed tool such as a chisel or screw driver (1) with one hand, insert one finger through the hole in the side gear and rotate the side gear back and forth to check the reading 0.004 in to 0.006 in.

Note: Increase the shim thickness to decrease the backlash. Decrease the shim thickness to increase the backlash.

17. If the reading is not within specifications, replace the shims until the proper specification is reached.




18. Install the locking cam (4), locking differential electronic coil (3), thrust bearing and bearing race (2), and the retaining ring (1) on the differential case (5).




19. Install the pins (1) in the differential case (2).





Note: The mating surfaces of the differential gear and the differential case must be clean and free of burrs before the installation of the differential gear.

20. Install the front differential gear on the differential case.

Caution: Refer to Fastener Caution (Fastener Caution).

Note: Hand start the differential gear bolts. The threads of the bolts are left hand thread.

21. Install the differential gear bolts and tighten in stages to 130 Nm (69 lb ft).




22. Place the differential case assembly on a block of wood.
23. Using the J 8092 - universal drive handle (1) and the J 25299 - side bearing installer (2), install the differential bearing. Repeat this procedure for the opposite differential bearing.