Drive, Final: Assembly: Assembly

Fig 1: Identifying Thrust Washer

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1 - THRUST WASHER

NOTE:

The differential is serviced as an assembly. Differential service is limited to bearing cups and cones. Any other differential component failure must be remedied by differential assembly and transfer shaft replacement.

Install side gear thrust washer (1) to differential case.

Fig 2: Identifying Differential Side Gear
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1 - DIFFERENTIAL SIDE GEAR

Install side gear (1) to differential case.

Fig 3: Identifying Pinion Gear, Tab, Notch & Washer

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1 - PINION GEAR

2 - TABBED WASHER

3 - LOCATING TAB

4 - NOTCH

Install both pinion gears (1) and washers (2) to case, while orientating washer tabs to notch in case.

Fig 4: Identifying Pinion Shaft
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1 - PINION SHAFT
Install pinion shaft (1).

Fig 5: Removing/Installing Side Gear
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1 - DIFFERENTIAL SIDE GEAR
Install side gear (1) to case.

Fig 6: Identifying Side Gear Thrust Washer
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1 - SIDE GEAR THRUST WASHER
Install side gear thrust washer (1) to case.

Fig 7: Identifying Differential Support And Case
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1 - DIFFERENTIAL SUPPORT

2 - DIFFERENTIAL CASE
Install differential support (1) into position, while aligning through-holes.

Fig 8: Identifying Differential Case And Ring Gear
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1 - DIFFERENTIAL CASE

2 - RING GEAR

Install differential ring gear (2) to case (1).

Fig 9: Identifying Differential Case, Pinion Shaft Retainer, Ring Gear, And Ring Gear-To-Case Bolts

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1 - DIFFERENTIAL CASE

2 - PINION SHAFT RETAINER

3 - RING GEAR

4 - RING GEAR-TO-CASE BOLT

NOTE:

New bolts must be used.

Install ring gear-to-case bolts, with pinion shaft retainers, and tighten bolts (4) to 95 N.m (70 ft. lbs.).
Check differential side gear turning torque using Differential Bearing Torque Tool C- 4995-1. Turning torque should be no more than 10 to 20 in-lbs (drag). If drag exceeds 20 in-lbs decrease shim size, if the drag is less than 10 in-lbs (drag) increase shim size.

Fig 10: Installing Differential Pinion Side Bearing
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Using Installer (special tool #6888, Installer, Seal) (1) and a press (2), install differential bearing (3) to pinion side of the differential housing.

Fig 11: Installing Ring Gear Side Bearing
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Using Installer (special tool #C-4213, Installer, Bearing) (2) and a press (1), install differential bearing (3) to ring gear side of the differential.

Fig 12: Installing Large Side Pinion Bearing
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Using Installer MD998911 (1) and a press, install the large pinion bearing to the pinion shaft.

Fig 13: Installing Small Side Pinion Bearing
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Using Installer (special tool #9723, Installer, Bearing) (1) and a press, install the small pinion bearing to the pinion shaft.