Locking Differential Assemble 10.5 Inch Axle

Note: The left and right side gear backlash and thrust block thickness measurement must be completed before the components of the differential can be assembled.

1. Install the right side differential side gear shim into the right differential case half.



2. Install the locking differential side gear cam unit and clutch disc assembly.



3. Install the latching bracket and spring assembly.



4. Install the governor assembly.



5. Position the straight end of the latching bracket spring over the governor assembly shaft.



6. Install the locking differential spider, the differential pinion gears, and the differential pinion gear thrust washers into the differential case.



7. Install the thrust block.



8. Install the left side differential side gear shim into the left differential case half.



9. Install the left side clutch disc assembly.



10. Install the locking differential side gear.



11. Install the left case half to the right case half.

Hold the left side locking differential side gear and clutch disc assembly in the left side case half.

Align the governor and latching bracket assembly shaft with the holes in the left case half.

12. Turn the differential case over onto the left case half.

Caution: Refer to Fastener Caution in the Preface section.




13. Install the differential case screws.

Tighten
Tighten the differential case screws to 17 N·m (13 lb ft).

14. Install the ring gear. Refer to Drive Pinion and Ring Gear Replacement.
15. Install the differential side bearings. Refer to Differential Side Bearings Replacement.

Locking Differential Assemble 8.6, 9.5, 11.5 Inch Axles

Note: The left and right side gear backlash and thrust block thickness measurement must be completed before the components of the locking differential can be assembled.

1. Install the left side gear thrust washer.



2. Install the left side gear cam unit and clutch disc assembly.
3. Install the right side gear thrust washer.
4. Install the right side clutch disc assembly.
5. Install the right side gear.

Note: 

•	If the original pinion gears and thrust washers are being re-used, install the pinion gears and thrust washers on the same side as when removed.

•	Place the pinion gears and the pinion thrust washers 180 degrees apart.

6. Install the pinion gear and the pinion thrust washers.
7. Rotate the pinion gears and the pinion thrust washers 90 degrees and align the pinion gears with the pinion shaft opening in the differential case.

Note: The open side of the thrust block must face the window opening.

8. Install the thrust block.

Note: Tighten the pinion shaft lock bolt finger tight.

9. Install the pinion shaft and the NEW lock bolt.



10. Install the governor assembly.
11. Using a hammer and a brass drift, install the governor bushing until there is 0.25-1.27 mm (0.010-0.050 in) of shaft end play.




Note: The straight end of the latching bracket spring must be over and outside the governor assembly shaft.

12. Install the latching bracket assembly.
13. Using a hammer and a brass drift, install the latching bracket bushing until there is 0.000-0.051 mm (0.000-0.002 in) of shaft end play.

Caution: Refer to Fastener Caution in the Preface section.

14. Tighten the pinion shaft lock bolt to.

•	For the 8.6 inch axle, tighten the bolt to 36 N·m (27 lb ft).

•	For the 9.5LD axle, tighten the bolt to 50 N·m (37 lb ft).

15. Install the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement.