Special Tools

Important: If it is necessary to replace the left side gear, the right side gear, or the thrust washers, the entire differential must be adjusted. The differential is adjusted using selective thickness thrust washers between the side gears and the case and adjusting the pinion gear to side gear backlash.

1. Lubricate the pinion gears, the side gears, the thrust washers and locking components using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations .



2. Install the differential side gear thrust washer to the locking differential side gear.

If the original differential side gear thrust washer is not available, install a 1.000 mm (0.039 in) thrust washer.

3. Install the locking differential side gear and thrust washer into the ring gear side of the differential case.



4. Install the differential pinion gears and the thrust washers by doing the following:

4.1.	Position both pinion gears and each thrust washer into each side of the differential window.

Place the pinion gears 180 degrees across from each other.

4.2.	Rotate the differential side gears until both pinion gears are directly opposite the opening in the differential case.

Line up the pinion shaft opening in each of the pinion gears with the pinion shaft opening in the differential case.




5. Install the pinion shaft.
6. If the pinion shaft cannot be installed, remove the pinion gears and thrust washers, the locking differential side gear and differential thrust washer.
7. Install a smaller differential side thrust washer and re-install the locking differential side gear, the pinion gears and thrust washers and the pinion shaft.



8. Install the pinion shaft lock bolt.

Do not torque the pinion shaft lock bolt at this time.




9. Measure the backlash of the pinion gear closest to the pinion shaft lock bolt and the locking differential side gear by doing the following:

9.1.	Rotate the pinion gear so that one of the teeth is perpendicular to the ring gear flange.

9.2.	Install a brass drift between the locking differential side gear and the pinion shaft in order to prevent the side gear from moving.

9.3.	Install the J 7872  (1) to the ring gear flange.

9.4.	Loosely clamp the J 7872-2 (2) and the J 8001-3  (3) onto the stem on the J 7872  (1).

9.5.	Install the J 7872-3 (4) to the J 8001-3  (3).

9.6.	Place the contact pad of the J 7872-3 (4) onto one of the teeth of the pinion gear closest to the locking differential side gear.

Preload the dial of the J 8001-3 approximately 3/4 of a turn clockwise.

9.7.	Tighten the lock nut of the J 7872-2 (2) finger tight.

9.8.	Turn the dial of the J 8001-3 until the needle and the dial face indicate ZERO.

9.9.	Pull the pinion gear firmly into the differential case seat.

9.10.

Rotate the pinion gear back and forth.

9.11.

Measure the backlash.

Specification
The backlash between the locking differential side gear and the pinion gears should be 0.051-0.076 mm (0.002-0.003 in).

10. If the backlash is too large, disassemble the differential, install the next larger size side gear thrust washer, re-assemble the differential and recheck the backlash.
11. If the backlash is too small, disassemble the differential, install next smaller size side gear thrust washer, re-assemble the differential and recheck the backlash.

Locking differential side gear thrust washers are available in the following sizes:

Washer Sizes

1. Remove the following from the differential case:

1.1.	The pinion shaft lock bolt

1.2.	The pinion shaft

1.3.	The pinion gears

1.4.	The pinion gear thrust washers

1.5.	The locking differential side gear

1.6.	The locking differential side gear thrust washer




2. Install the differential side gear thrust washer into the bell-end of the differential case.

If the original differential side gear thrust washer is not available, install a 1.000 mm (0.039 in) thrust washer.

3. Install the differential side gear into the bell-end of the differential case.



4. Install the differential pinion gears by doing the following:

4.1.	Position both pinion gears and each thrust washer into each side of the differential window.

Place the pinion gears 180 degrees across from each other.

4.2.	Rotate the differential side gears until both pinion gears are directly opposite the opening in the differential case.

Line up the pinion shaft opening in each of the pinion gears with the pinion shaft opening in the differential case.




5. Install the pinion shaft.
6. If the pinion shaft cannot be installed, remove the pinion gears and thrust washers, the locking differential side gear and differential thrust washer.
7. Install a smaller differential side thrust washer and re-install the locking differential side gear, the pinion gears and thrust washers and the pinion shaft.



8. Install the pinion shaft lock bolt.

Do not torque the pinion shaft lock bolt at this time.




9. Measure the backlash of the pinion gear closest to the pinion shaft lock bolt and the differential side gear by doing the following:

9.1.	Rotate the pinion gear so that one of the teeth is perpendicular to the ring gear flange.

9.2.	Install a brass drift between the locking differential side gear and the pinion shaft in order to prevent the side gear from moving.

9.3.	Install the J 7872  (1) to the ring gear flange.

9.4.	Loosely clamp the J 7872-2 (2) and the J 8001-3  (3) onto the stem on the J 7872  (1).

9.5.	Install the J 7872-3 (4) to the J 8001-3  (3).

9.6.	Place the contact pad of the J 7872-3 (4) onto one of the teeth of the pinion gear closest to the locking differential side gear.

Preload the dial of the J 8001-3 approximately 3/4 of a turn clockwise.

9.7.	Tighten the lock nut of the J 7872-2 (2) finger tight.

9.8.	Turn the dial of the J 8001-3 until the needle and the dial face indicate ZERO.

9.9.	Pull the pinion gear firmly into the differential case seat.

9.10.

Rotate the pinion gear back and forth.

9.11.

Measure the backlash.

Specification
The backlash between the locking differential side gear and the pinion gears should be 0.051-0.076 mm (0.002-0.003 in).

10. If the backlash is too large, disassemble the differential, install the next larger size side gear thrust washer, re-assemble the differential and recheck the backlash.
11. If the backlash is too small, disassemble the differential, install next smaller size side gear thrust washer, re-assemble the differential and recheck the backlash.

Differential side gear thrust washers are available in the following sizes:

Washer Sizes