7.5" & 8.8" Differential Case & Ring Gear
- Lubricate each steel clutch plate, and soak friction plates with additive friction modifier for 15 minutes. Assemble differential clutch packs without shims on respective differential side gears. Place base portion of Mandrel (T80P-4946-A) in vise. Install differential clutch pack and differential side gear without shim on gauge.
- Position Differential Clutch Gauge (T80P-4946-A) hand-tight on top of differential pack. Install differential clutch gauge over disc and clutch pack. Install nut of clutch gauge over top and base stud.
- Using feeler gauge, select thickest blade that will enter between tool and differential clutch pack. See Fig 1 . The reading will be the thickness of new clutch shim. See CLUTCH PACK SHIM SIZES .
- Remove feeler gauge from clutch pack and side gear assembly. Install shims on clutch pack and side gear assembly. Install differential side gears in differential case. Install differential pinion gears with differential pinion thrust washers in differential case.
- Using soft-faced hammer, install differential clutch spring. Install differential pinion shaft and new differential pinion shaft lock bolt finger-tight.
- Place Traction-Lok Torque Tool (205-022/T66L-4204-A) in a vise. Position carrier on Torque Tool and measure rotating torque. Rotating torque should be 20 ft. lbs. (27 N.m). See Fig 2 .
- This checks torque required to rotate one side gear while other is held stationary. If clutch plates are used, break-away torque should be at least 20 ft. lbs. (27 N.m) and rotation should be smooth. If clutch plates are new, break-away torque may vary and be slightly higher than specification.
- If break-away torque is as specified and rotation is smooth, tighten pinion shaft lock bolt to proper specification. See TORQUE SPECIFICATIONS . Install differential bearings. If sensor ring has been removed, align notch on new sensor ring with notch on case flange and install new ring. Install ring gear bolts. Install differential case.
NOTE:
If new pinion shaft lock bolt is unavailable, coat threads with threadlock and sealer prior to installation.