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Rear Axle Assembly: Reassembly

  1. If new components have been installed, proper gear set assembly must be checked using Pinion Depth Gauge (T79P-4020-A) to determine correct pinion shim thickness. See PINION DEPTH  under ADJUSTMENTS.
  2. Install new bearing cups in axle housing if necessary. Bearing cups must be seated in bores so that a .0015" (.038 mm) feeler gauge will not fit between bearing cup and bottom of bore.
  3. Install necessary shims on pinion to obtain correct pinion depth. Press inner bearing on pinion shaft. Ensure bearing is seated against shims. Lubricate pinion bearings with gear lubricant. Install pinion in axle housing. Install new collapsible spacer and outer pinion bearing.
  4. Verify sealing surfaces are clean and free of burrs. Using Seal Installer (T79P-4676-A), install oil seal. If oil seal becomes cocked during installation, remove and replace. Lubricate oil seal lips with multipurpose lubricant.
  5. Check pinion and companion flange splines for burrs. Coat companion flange splines with small amount of gear lubricant. Align marks on companion flange and pinion on used pinion only. Install companion flange on pinion. Coat washer side of NEW pinion nut with gear lubricant and install.
  6. Using Companion Flange Holder (T78P-4851-A), hold companion flange and gradually tighten pinion nut. See TORQUE  SPECIFICATIONS table at end of this article. DO NOT  hammer on companion flange or install with power tools. Rotate pinion and check pinion bearing preload often until correct preload is obtained. See PINION BEARING PRELOAD  .
    NOTE: If desired preload is exceeded, a new collapsible spacer must be installed and nut retightened until proper preload is obtained.
  7. Lubricate all parts with gear axle lubricant. Place side gears and thrust washers into differential case. Place pinion gears and thrust washers exactly opposite each other in differential case openings and mesh with side gears.
  8. Install ring gear with new mounting bolts. Apply Loctite to bolt threads. Tighten the bolts to proper specification. See TORQUE SPECIFICATIONS  table. Press new bearings on differential cases using proper sized sleeve. Ensure bearings are fully seated on differential cases.
  9. After proper shims have been chosen to obtain proper ring gear backlash and bearing preload, differential assembly may be installed. See DIFFERENTIAL BEARING PRELOAD & RING GEAR BACKLASH  in ADJUSTMENTS.
  10. Install differential assembly and bearing cups in axle housing. Install bearing caps and bolts. Tighten bearing cap bolts to specification. See TORQUE SPECIFICATIONS  table at end of this article.
  11. Check ring gear backlash and gear tooth contact pattern. See GEAR TOOTH PATTERNS  . Gear tooth contact pattern does not need to be checked if pinion depth gauge is used and backlash is correct. Pinion depth and ring gear backlash may be adjusted to obtain proper gear tooth contact pattern.
  12. Once all adjustments are correct, install axle shafts, housing cover, brake drums and wheels. Install drive shaft. Check reference mark alignment. Fill axle housing with hypoid gear lubricant.
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