Tools Required

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.

1. Tighten the right sleeve using the J 33792 .

Tighten
Tighten the right sleeve to 140 N·m (103 lb ft).




2. Tighten the left sleeve using the J 42213 .

Tighten
Tighten the left sleeve to 140 N·m (103 lb ft).




3. Mark the location of the adjusting sleeves in relation to the carrier halves (1) in order to count the notches in the adjusting sleeves when turned.
4. Turn the right adjusting sleeve out two notches using the J 33792 .
5. Turn the left adjusting sleeve in one notch using the J 42213 .
6. Rotate the pinion several times in order to seat the bearings.



7. Install the J 8001 in order to ensure that the button contacts the outer edge of the pinion yoke. The plunger must be at a right angle to the pinion yoke.
8. Move the pinion yoke through the yoke's free play while holding the differential case. Record the dial indicator reading.
9. Divide the dial indicator reading by two in order to obtain the actual backlash. For example, a dial indicator reading of 0.16 mm (0.006 in) means that there is actually 0.08 mm (0.003 in) backlash.
10. Inspect and record the backlash at three or four points around the ring gear.

•	Hold the case stationary when checking backlash.

•	If the backlash varies more than 0.05 mm (0.002 in), inspect for the following conditions:

-

Burrs

-	A distorted case flange

-	Uneven bolting conditions

-	Foreign matter between the case and the ring gear

•	Gear backlash should be between 0.08-0.25 mm (0.003-0.010 in) with a preferred specification of 0.013-0.018 mm (0.005-0.007 in).

•	If the backlash is incorrect, adjust the sleeves as necessary. Maintain one notch preload on the side bearings. For example, if the right sleeve needs to be turned out one notch, turn in the left sleeve one notch.

•	In order to increase backlash, turn the left sleeve in and turn the right sleeve out the same amount. In order to decrease backlash, turn the right sleeve in and turn the left sleeve out the same amount.

11. When the backlash is correct, mark the position of the sleeves in order to keep the sleeves in the same location.