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.

Locking Differential Assemble 10.5 Inch Axle

Important: 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.

Notice: Refer to Fastener Notice 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 .