Tools Required

1. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.



2. Install the inner pinion bearing onto the pinion gear using the J 33785 .
3. Install the new collapsible spacer onto the pinion gear.
4. Lubricate the inner and the outer pinion bearing with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.



5. Install the new deflector onto the pinion yoke using a soft-faced hammer.
6. Install the outer pinion bearing.



7. Install the oil seal by doing the following:

7.1.	Install the differential carrier assembly into a vise.

Place shop towels in the vise in order to protect the differential carrier assembly.

7.2.	Position the oil seal in the bore.

7.3.	Install the J 33782 over the oil seal.

7.4.	Strike the J 33782 with a hammer until the seal flange seats on the axle housing surface.

8. Install the pinion gear, with the inner pinion bearing and the new collapsible spacer, into the differential carrier case.
9. Apply sealant, P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
10. Install the pinion yoke.

Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.

11. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
12. Install the washer and a new pinion nut.



13. Install the J 8614-01 onto the pinion yoke as shown.

Notice: Refer to Fastener Notice in the Preface section.

Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.

14. Tighten the pinion nut while holding the J 8614-01 .

Tighten
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.

15. Measure the rotating torque of the pinion using an inch-pound torque wrench.

Specification
The rotating torque of the pinion should be 1.0-2.3 N·m (10-20 lb in) for used bearings or 1.7-3.4 N·m (15-30 lb in) for new bearings .

16. If the rotating torque measurement is below 1.0 N·m (10 lb in) for used bearings or 1.7 N·m (15 lb in) for new bearings, continue to tighten the pinion nut.

Tighten
Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.0-2.3 N·m (10-20 lb in) for used bearings or 1.7-3.4 N·m (15-30 lb in) for new bearings.

17. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.

Recheck the rotating torque and adjust if necessary.




18. Install the left side differential carrier bearing, print side out, to the left side differential adjuster nut using the J 45232  (2) and the J 8092  (1).



19. Install the left side differential bearing adjuster into the left differential carrier case half using the J 42213 .



20. Install the left differential case side bearing cup into the left differential carrier case half using the J 23423-A and the J 8092 .



21. Install the right side differential carrier bearing, print side out, to the right side differential adjuster nut using the J 45233  (2) and the J 8092  (1).



22. Install the right side differential bearing adjuster into the right side differential carrier case half using the J 45224 .
23. Install the right differential case side bearing cup into the right differential carrier case half J 23423-A and the J 8092 .



24. Install the differential case assembly into the left differential carrier case half.
25. Install the right differential carrier case half to the left differential carrier case half.

Do not use sealer at this time.

If the carrier case halves do not make complete contact, back out the right side differential adjuster using the J 45224 .

26. Install the differential carrier case bolts.

Tighten
Tighten the differential carrier case bolts to 48 N·m (35 lb ft).

27. Using the J 45224 , turn the left differential adjuster nut clockwise until the differential adjuster nut contacts the differential side bearing and can no longer be turned.
28. Using the J 45224 , turn the right differential adjuster nut sleeve clockwise until the differential adjuster nut contacts the differential side bearing and can no longer be turned.
29. Rotate the pinion several times in order to seat the bearings.
30. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench.

Specification
The rotating torque of the pinion and differential assembly should be 2.8-5.1 N·m (25-45 lb in) for used bearings, or 3.4-6.2 N·m (30-55 lb in) for new bearings.

31. If the rotating torque measurement is below 2.8 N·m (25 lb in) for used bearings, or 3.4 N·m (30 lb in) for new bearings, tighten the differential adjuster nuts in one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
32. If the rotating torque measurement is above 5.1 N·m (45 lb in) for used bearings, or 6.2 N·m (55 lb in) for new bearings, loosen the differential adjuster nuts in one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications.
33. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.

Recheck the rotating torque and adjust if necessary.

34. Measure the drive pinion to ring gear backlash. Refer to Backlash Inspection and Adjustment .