Locking Differential Assemble 10.5 Inch Axle

1. Install the right thrust washer.
2. Install the right cam unit. Refer to Cam Unit Assembly in this section.
3. Install the following parts:

•	The reaction blocks

•	The reaction block thrust washer

•	The pinion yoke

•	The pinion gears

•	The pinion thrust washers




4. Install the left thrust washer.

Assemble the plates as shown.

5. Install the left side gear.
6. Install the latching bracket assembly.
7. Install the governor assembly.

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

8. Install the case halves together.

Hold the side gear in the left side case half.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

9. Install the differential case screws.

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

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

Locking Differential Assemble 8.6, 9.5 Inch Axles

1. Install the left side gear thrust washer.
2. Install the cam unit assembly. Refer to Locking Differential Cam Unit Assemble .
3. Install the right side gear thrust washer.
4. Install the right side clutch plates.
5. Install the right side gear.
6. Install the thrust block, the pinion thrust washer, and the pinion gear.

Place the pinion gears 180 degrees apart.

7. Rotate the gears and the thrust block into position.

The open side of the thrust block must fact the window opening.

8. Install the pinion shaft.
9. Install the new pinion shaft lock bolt.

Tighten the pinion shaft lock bolt finger tight.

10. Install the governor assembly, and the latching bracket.

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

11. Install the stop pin (9.5 inch axle only).

Press the pin in flush with the differential case.

Important: Use only a bushing with a straight hole, not a tapered hole.

12. Using a press, install the governor bushing.

Specification
Press the bushing into place until there is 0.25-1.27 mm (0.010-0.050 in) of shaft end play.

Important: Some 9.5 inch locking differentials have a latching bracket bushing with a tapered hole. Use only a bushing with a tapered hole, not a straight hole.

13. Using a press, install the latching bracket bushing.

Press the bushing in far enough to eliminate all end play.