Differential Assembly (A-540E) Disassembly & Reassembly: Reassembly

Install right oil seal to retainer. Drive in NEW oil seal until seal surface is flush with surface of retainer. Coat oil seal lip with grease.
Install original adjusting shim and bearing outer race to left bearing retainer. Shim should be .0945" (2.400 mm). Press outer race into left retainer. Install oil baffle and oil seal after adjusting differential side bearing preload. See TRANSAXLE REASSEMBLY .
Assemble differential case. Coat all sliding and rotating surfaces with ATF before assembly. Install thrust washer to side gear. Install pinions and thrust washers to spider. Install side gear and spider with pinions to differential left case. Using a dial indicator, measure side gear backlash while holding one pinion against carrier casing. See Figure. Backlash should be .002-.008" (.05-.20 mm). Install side gear and spider with pinions to right side of differential case. Check pinion gear backlash.
Select side gear thrust washer which ensures backlash is within specification. Side gear thrust washers are available in thicknesses from .0315" (.80 mm) to .0551" (1.40 mm) in .004" (.10 mm) increments. Select washers of the same size for both sides. Install speedometer driven gear.
Align match marks on differential cases. Using plastic hammer, carefully tap differential right case. Using a Torx wrench, install and tighten 16 Torx screws to 46 ft. lbs. (63 N.m).
Clean differential case contact surface with cleaning solvent. Heat ring gear to about 212°F (100°C) in an oil bath. DO NOT heat ring above 230°F (110°C). Clean contact surface of ring gear with cleaning solvent. Quickly install ring gear on differential case. Tighten bolts to 91 ft. lbs. (124 N.m). Install right and left side bearing to differential case.

Fig 1: Exploded View Of Differential Assembly (A-540E)