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Differential Assembly: Reassembly

  1. Coat all side gears, pinion gears and thrust washers with grease. Install side gears and side gear thrust washers in differential carrier.
  2. Install pinion gears in place exactly opposite each other in mesh with side gears. Install pinion gear thrust washers behind pinion gears.
  3. Rotate side gears until pinion gears are aligned with pinion shaft hole in differential carrier. Install pinion shaft and NEW pin.
  4. Install ring gear. Install and tighten ring gear bolts to specification in a crisscross pattern. See TORQUE SPECIFICATIONS  . Using press and Adapter (07MAD-PR90100), install differential carrier bearings on differential carrier (if removed).
  5. If installing bearing races for drive pinion in differential case, install thrust washer, located behind bearing race, in differential case. On 1991 models, use Shaft (07JAF-SJ80110)) and Bearing Race Installers (07MAF-SPOO110) and (07MAF-SPOO120) to install bearing races. On 1992 models, use Shaft (07MAF-SPOO13A) and Bearing Race Installers (07MAF-SPOO11A) and (07MAF-SPOO12A) to install bearing races.
  6. On all models, install drive pinion bearing races in differential case starting with outer bearing race (lock nut side) and then inner bearing race.
    CAUTION: Heat differential case to 212°F (100°C) to assist in bearing race installation. DO NOT  exceed 212°F (100°C or differential case may be damaged.
  7. If installing bearing races for differential carrier bearings, install NEW thrust shim in differential case or differential case cover. Ensure thrust shim is the same thickness as thrust shim that was removed. Using hammer, Driver (07749-0010000) and Adapter (07GAD-SD40101), drive bearing race into differential case and differential case cover.
  8. If original drive pinion and ring gear are being installed, install original thickness drive pinion thrust shim on drive pinion (if removed). If a NEW drive pinion and ring gear are being installed, the proper thickness of drive pinion thrust shim must be determined to obtain the correct drive pinion height. Refer to DRIVE PINION HEIGHT  under ADJUSTMENTS near the end of this article.
  9. If installing pinion bearing on drive pinion, use press, old pinion spacer, Driver (07746-0030100) and Adapter (07746-0030400). Install pinion bearing, old pinion spacer, adapter and then driver on drive pinion. Press pinion bearing onto drive pinion. Lubricate all pinion bearings with oil.
  10. Install drive pinion in differential case. DO NOT  install pinion spacer and thrust washers at this time. Install pinion bearing on drive pinion.
  11. Using hammer and Driver (07746-0030100), drive outer pinion bearing onto drive pinion while supporting drive pinion. Install thrust washer, drive pinion hub, thrust washer and lock nut.
  12. Tighten lock nut to 15 ft. lbs. (20 N.m). Clean drive pinion and ring teeth and coat with Prussian Blue. Lubricate differential carrier bearings with oil.
  13. Install differential carrier into differential case. Install differential case cover. Tighten differential case cover bolts in a crisscross pattern to 33 ft.lbs. (45 N.m).
  14. Install Wrench (07LLA-SM40200) for 1991 models or (07MAA-SF10100) for 1992 models in differential assembly. See Figure . Rotate ring gear both directions while applying resistance to pinion shaft.
  15. Remove differential cover and inspect ring gear tooth contact pattern. Correct gear tooth contact should be centered on the ring gear. See DRIVE AXLE - GEAR TOOTH CONTACT PATTERNS article in the DRIVE AXLES section.
  16. If gear tooth contact pattern is incorrect, drive pinion height must be changed to correct gear tooth contact pattern. Change drive pinion thrust shim located below bearing on drive pinion to adjust drive pinion height.
  17. If gear tooth contact pattern is correct, remove components from drive pinion for installation of pinion spacer. Install NEW pinion spacer and thrust washers on drive pinion.
  18. Install outer pinion bearing on drive pinion. Using hammer and driver, drive outer pinion bearing onto drive pinion while supporting drive pinion.
  19. Install thrust washer, drive pinion hub, thrust washer and a NEW lock nut on the drive pinion. Check the pinion bearing preload. Refer to PINION BEARING PRELOAD  under ADJUSTMENTS near the end of this article.
  20. Once correct pinion bearing preload is obtained, stake lock nut against drive pinion. Clean drive pinion and ring teeth and coat with Prussian Blue. Lubricate differential carrier bearings with oil.
  21. Install differential carrier into differential case. Install differential case cover. Tighten differential case cover bolts in a crisscross pattern to 33 ft.lbs. (45 N.m).
  22. Check TOTAL BEARING PRELOAD. See TOTAL BEARING PRELOAD  under ADJUSTMENTS. Once correct total bearing preload is correct, check ring gear backlash. See RING GEAR BACKLASH  under ADJUSTMENTS.
  23. Once correct ring gear backlash is obtained, remove differential case cover and differential assembly. Check gear tooth contact pattern. Correct gear tooth contact should be centered on the ring gear. See DRIVE AXLE - GEAR TOOTH CONTACT PATTERNS article in the DRIVE AXLES section.
  24. Install breather plate on differential case cover (if removed). Install breather plate bolts and tighten to specification. Stake heads of bolts against differential case cover.
  25. Install oil guide pipe, oil cooler and NEW "O" rings. Tighten oil guide pipe bolt and oil cooler nuts to specification. Install coolant pipes, NEW seal washers and coolant pipe joint bolts. Tighten coolant pipe joint bolts to specification.
  26. Install differential assembly. Apply Liquid Gasket (08718-0001) to differential case cover. Install differential case cover. Install and tighten bolts to specification in a crisscross pattern.
  27. Using hammer, Driver (07749-0010000) and Adapter (07965-SA00600), install oil seal in differential case cover. Using hammer, Driver (07749-0010000) and Adapter (07MAD-SP00200), install oil seal for drive pinion.
NOTE: Ensure oil seal for drive pinion is installed so distance from end of differential case to the top surface of oil seal is .610-.630" (15.50-16.00 mm).
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