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Reassembly & Adjustment: Differential

  1. Install side gears and thrust washers in differential case. Thrust washers should be same size for both sides if possible. Install pinion gears with thrust washers and tap pinion shaft into place. Check side gear backlash while holding one pinion gear toward case.
  2. If backlash is incorrect, change thickness of thrust washers until backlash is within specification. See AXLE ASSEMBLY SPECIFICATIONS . Install lock pin through case and hole in pinion shaft. Stake pin to differential case. Press side bearings onto case.
  3. Clean contact surfaces of differential case. Heat ring gear to 212°F (100°C) in oil bath. Clean ring gear contact surface with solvent and install on case while still hot. Align index marks on ring gear and case. Coat ring gear bolts with hypoid oil and install with lock plates.
    CAUTION: Do not heat ring gear above 230°F (110°C).
  4. Tighten ring gear bolts gradually in diagonal sequence. Stake lock plates with one tab flush against flat of bolt head. Tab resting on point should be staked on tightening side of point.
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