Front Differential Case Assemble 8.25 Inch Axle

Special Tools

1. Lubricate the pinion and side gears using axle lubricant. Use the correct fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers .



2. Install the thrust washers and the differential side gears into the differential case.

If the same differential side gears and the thrust washers are being used, install the gears and the washers to the original locations.




3. Install the differential pinion gears by performing the following steps:

3.1.	Position both pinion gears between the differential side gears directly opposite of each other.

3.2.	Rotate the differential side gears until the pinion gears are opposite the opening in the differential case in line with the pinion shaft opening.

4. Install the thrust washers.

Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers.




5. Install the pinion gear shaft.
6. Install the new pinion gear shaft lock pin using a hammer and a brass drift.




Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

7. Install the ring gear onto the differential case.




Important: The ring gear bolts have left-hand threads.

8. Install the new ring gear bolts.

Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

Notice: Refer to Fastener Notice in the Preface section.

9. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

Tighten
Tighten the ring gear bolts in sequence to 120 N·m (89 lb ft).




10. Install the differential side bearings by performing the following steps:

10.1.

In order to protect the differential case, install the J 8107-2 in the case on the side opposite the bearing installation.

10.2.

Install the J 22761  (2) and the J 8092  (1) onto the differential case bearing as shown.

10.3.

Drive the differential case bearing onto the case using the J 22761 and the J 8092 .

Front Differential Case Assemble 9.25 Inch Axle

Special Tools

1. Apply lubricate to the pinion and side gears using the correct lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers .




Important: If reusing the differential side gears and the thrust washers, install them in their the original locations.

2. Install the thrust washers and the differential side gears into the differential case.



3. Position both pinion gears between the differential side gears directly opposite of each other.
4. Rotate the differential side gears until the pinion gears are opposite the opening in the differential case in line with the pinion shaft opening.
5. Using a hammer and brass drift, install the thrust washers in between the pinion gear and differential case .
6. Install the differential side gear spacers, if equipped.



7. Install the pinion gear shaft.

Notice: Refer to Fastener Notice in the Preface section.




8. Install the pinion shaft lock bolt.

Tighten
Tighten the pinion shaft lock bolt to 53 N·m (39 lb ft).





Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

9. Install the ring gear onto the differential case.




Important: The ring gear bolts have left-hand threads.

10. Hand start each of the NEW ring gear bolts.

Important: Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

11. Install the new ring gear bolts.

Tighten
Tighten the ring gear bolts in sequence to 138 N·m (102 lb ft).




12. In order to protect the differential case, install the J 36597 in the case on the side opposite the bearing installation.
13. Install the J 29710  (2) and the J 8092  (1) onto the differential case bearing as shown.
14. Using the J 29710 and the J 8092 , install the differential case bearing onto the case.