Tool Required

J 42178 Differential Side and Pinion Alignment Kit

1. Place the differential carrier on the J 42178 , clamped in the vice, with the ring gear flange downwards.



2. Install the counterpiece of the J 42178 into the opposing differential carrier bore (1).



3. Install a NEW differential pinion gear retaining ring (1) into the differential carrier (2).
4. Thoroughly clean all the components.



5. Place the shims on the differential side gears.

5.1.	Coat the gears with rear axle lubricant.

5.2.	Coat the shims with rear axle lubricant.

5.3.	Install the thicker shim (the shim has notches around the outer edge) (3) toward the carrier.

5.4.	Install the thinner (conical) washer toward the differential side gear (1).

6. Place the differential side gears with the previously installed shims into the differential carrier and onto both of the pieces of the J 42178 .



7. Lubricate with gear lubricant and engage the differential pinion gears (2) and engage the conical washers (1) with the differential side gears to align. Align them so that they are exactly opposite each other in the carrier window. This may require the use of a helper.
8. Move the differential pinion gear conical washers (1) forward in the intended rotational direction so that they will start or lead the pinion gears (2) into the mounting position.
9. Use a ratchet to rotate the J 42178 to draw the pinion gears into position. Ensure that the conical washers also move into position. It may be necessary to use a drift and a small hammer to assist the washers into the position. The pinion gears typically move into position quicker and easier than the conical washers do.



10. Use a deadblow hammer to drive the rear axle pinion gear shaft (1) into its carrier bore (2) after aligning the differential pinion gears and washers with the pinion gear shaft bores.

Important: Because of the tension of the retaining ring, it may be necessary to recruit a helper to use a small screwdriver to keep the ring centered in its bore while the shaft (1) is driven in.

11. Attach a torque wrench to the J 42178 .



12. Check for proper pinion rotating torque and check for proper side gear rotating torque. The acceptable rotating torque should read between 11 and 22 lb ft.
13. Heat the ring gear to approximately 100°C (212°F). DO NOT overheat!
14. Install the ring gear onto the differential carrier.



15. Install NEW ring gear bolts.

Tighten
The ring gear bolts must be torqued in the sequence shown to 115 N·m (85 lb ft).