Tools Required

Important: 

1. Install the drive pinion, if necessary. Refer to Drive Pinion and Ring Gear Replacement .
2. Measure the rotating torque of the drive pinion using an inch-pound torque wrench.

Specification
The rotating torque of the drive pinion should be 1.7-3.4 N·m (15-30 lb in) for new bearings or 1.1-2.3 N·m (10-20 lb in) for used bearings.

3. Record the measurement.
4. Determine the total service shim thickness for the axle without preload by doing the following:

Important: Before installation of the case assembly, ensure that the side bearing surfaces in the carrier are clean and free of burrs. If the original bearings are to be reused, the original bearing cups must also be used.

3.1.	Install the differential case with the side bearings and bearing cups.

3.2.	Insert one 4.318 mm (0.170 in) thick service spacer on the left side or ring gear side of the case.

3.3.	Install the J 22779 between the differential case and the axle housing on the right side.

Important: Over-tightening may spread the housing and result in incorrect shim selection.

3.4.	Tighten the knob on the J 22779 until there is moderate drag when the J 22779 is moved.

3.5.	Remove the J 22779 and the service spacer.

3.6.	Measure the J 22779 in 3 locations.

3.7.	Calculate the average of the 3 measurements.

Record the measurement.

3.8.	Measure the service spacer.

Record the measurement.

3.9.	Add the thickness of the service spacer to the average thickness of the J 22779 .

The resulting value is the total service shim thickness without preload for the axle.

5. Determine the service shim thickness for the left side of the axle without preload by doing the following:

4.1.	Insert one 1.016 mm (0.040 in) service shim between the differential case and right side axle housing.

4.2.	Insert one BENT 1.016 mm (0.040 in) service shim between the differential case and the service shim.

4.3.	Install the J 22779 on the left side of the differential case.

4.4.	Tighten the knob on the J 22779 until there is slight amount of backlash between the ring and pinion gears.

4.5.	Install the J 25025-1 onto the differential housing.

4.6.	Install the J 8001-3 onto the J 25025-1 .

4.7.	Position the button of the J 8001-3 against the ring gear.

4.8.	Preload the dial of the J 8001-3 .

Align the needle and the dial face of the J 8001-3 to ZERO.

4.9.	While holding the drive pinion stationary, measure the backlash between the drive pinion and the ring gear.

Specification
The backlash between the drive pinion and the ring gear should be 0.0254-0.0508 mm (0.001-0.002 in).

4.10.

If the backlash is not within specification, tighten or loosen the knob on the J 22779 as necessary until the proper backlash is obtained.

4.11.

Remove the J 8001-3 .

4.12.

Remove the J 25025-1 .

4.13.

Remove the J 22779 and measure the thickness in 3 locations.

4.14.

Calculate the average of the 3 measurements.

This value is the left side service shim thickness without preload.

6. Remove the differential case with the differential side bearings and the bearing cups.
7. Subtract the service shim thickness for the left side of the axle (calculated in step 4.14) from the total service shim thickness (calculated in step 3.9).

This value is the service shim thickness for the right side of the axle without preload.

8. In order to initially set the preload of the differential case bearings and the backlash to approximately 0.127-0.2286 mm (0.005-0.009 in), take the value determined in step 6 and add 0.2032 mm (0.008 in) service shim thickness to this amount.
9. Assemble the left and right side shim packs using one 4.318 mm (0.170 in) service spacer on each side and the appropriate amount of service shims.

Measure the service spacer and the service shims separately.

Add the measurements together in order to determine the total shim pack thickness.

10. Install the differential case with the differential side bearings and the bearing cups.
11. Install the left side service spacer between the axle housing and the differential case.
12. Install the right side service spacer between the axle housing and the differential case.
13. Install the left side service shim or shims using the J 25588 , if necessary.

The service shim or shims must be installed between the service spacer and the differential bearing cup.

14. Install the right side service shim or shims using the J 25588 , if necessary.

The service shim or shims must be installed between the service spacer and the differential bearing cup.

Notice: Refer to Fastener Notice in the Preface section.

15. Install the differential bearing caps and bolts.

Tighten
Tighten the differential bearing cap bolts to 75 N·m (55 lb ft).

16. Measure the drive pinion and differential case side bearing preload using an inch-pound torque wrench.

Rotate the pinion several times to ensure the bearings have seated.

Specification
The rotating torque of the drive pinion and differential case bearings should be 3.9-6.2 N·m (30-55 lb in) for new bearings or 2.8-5.1 N·m (25-45 lb in) for used bearings.

17. Record the measurement.
18. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured in Step 2, from the drive pinion and differential case bearing preload, measured in Step 15.

Multiply the value obtained by the axle ratio.

Specification
The differential case side bearing preload should be 1.7-4.0 N·m (15-35 lb in).

19. If the differential case side bearing preload is not within specifications, add or subtract shim thickness equally from each shim pack as necessary in order to increase/decrease the side bearing preload.
20. Once the differential side bearing preload is correct, measure the backlash and adjust, if necessary. Refer to Backlash Adjustment .