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Differential Assembly: Reassembly

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  1. If installing new ring gear and pinion, and/or pinion bearings, see DRIVE PINION DEPTH  and SIDE BEARING PRELOAD  under ADJUSTMENTS. After installing original pinion shims onto pinion, install inner pinion bearing onto pinion using Bearing Installer (J-5590 for 7.6" ring gear, J-24433 for 8.0" and 8.6" ring gear and J-36614 for 9.5" ring gear). Drive bearing onto pinion until bearing is tightly seated against pinion shims.
  2. Install a NEW collapsible spacer onto pinion. Lubricate pinion bearings. Install pinion into axle housing. Install outer bearing onto pinion using Bearing Installer (J-5590 for 7.6" ring gear, J-24433 for 8.0" and 8.6" ring gear and J-36614 for 9.5" ring gear). Hold pinion in position from inside housing while driving bearing onto pinion. To install pinion oil seal and pinion flange, see PINION FLANGE & OIL SEAL  under REMOVAL & INSTALLATION.
  3. Install ring gear squarely onto differential case. Tighten ring gear bolts evenly and alternately to specification. Ring gear bolts are left-hand thread. See TORQUE SPECIFICATIONS .
  4. Lubricate pinion gears and side gears with gear oil. Install left and right gears and thrust washers into case as marked in disassembly. Install one pinion gear onto side gears and rotate gears until pinion gear is exactly opposite. Place second pinion gear onto side gears so that pinion gear holes are exactly opposite each other.
  5. Verify pinion shaft fits through both pinion gears for alignment purposes. Install pinion gear thrust washers. Hold pinion gears in position and carefully remove pinion shaft. Rotate side gears to position pinion gears in alignment with differential case holes. Install pinion shaft and pinion shaft lock bolt. Temporarily snug tighten lock bolt to specification. See TORQUE SPECIFICATIONS .
  6. If side bearings were removed, install side bearings to differential case using press or Bearing Installer (J-21784) for 7.6", 8.0" and 8.6" ring gear or (J-29710) for 9.5" ring gear. Before installing side bearing, install Adapter (J-8107-2) for 7.6" and 8.0" ring gear, (J-8107-4) for 8.6" ring gear or (J-36597) for 9.5" ring gear to opposite bearing end of differential case to protect case surface. Drive bearing onto case. Repeat for opposite side.
  7. Lubricate side bearings and install races. Install differential case into carrier housing. Install spacer between each bearing race and housing with chamfered edge of spacer against housing. Install right bearing cap and loosely tighten bolts so that differential case is free to move but will not fall out of housing. To complete installation, see SIDE BEARING PRELOAD  under ADJUSTMENTS.
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