Differential Case
- Mount differential case in vise. Use multipurpose grease to lubricate side gears, pinion gears and all thrust washers. Install components into case. Rotate side gears until holes in pinion gears and washers line up with holes in case.
- Install differential pinion shaft. Install lock pin. Using a punch and hammer, peen metal of differential case over lock pin at 90 degrees to left and right of lock pin slot.
- Align tab in anti-lock sensor ring with slot in differential case. Install 2 ring gear bolts, but DO NOT tighten. Using an arbor press, press sensor ring and ring gear onto differential case.
- Apply Thread Lock Sealer (EOAZ-19554-AA) to NEW ring gear bolts. Install NEW ring gear bolts and tighten evenly to specification. See TORQUE SPECIFICATIONS .
- On Dana 50 axle, install Master Differential Bearings (205-158) onto differential case. On Dana 60 axle, install Master Differential Bearings (205-D033). On Dana 80 axle, install Master Differential Bearings (205-D038). On all axles, install outboard spacers (if equipped) into case. Install case into housing (without shims).
- Mount dial indicator with indicator tip against back of ring gear, at 90 degrees to gear. Measure and record total end play of differential case by moving it back and forth with screwdriver. See Fig 1.
- This measurement will be used later to determine proper shim pack dimension. Remove case from housing. Leave master bearings on case at this time.
NOTE:
Tab on anti-lock sensor ring must be aligned with slot in differential case.