Usage:
(8) Torque for four studs ... 320 ± 30 lb. ft.(435 ± 40 N·m)
(14) 9D19 Shim thickness ... .005 in.(0.13 mm)
9D21 Shim thickness ... .007 in.(0.18 mm)
(15) Torque for 36 bolts ... 320 ± 10 lb. ft.(435 ± 14 N·m)
NOTE: On differential with flat washers, put 5P2506 Anti-Seize Compound on face of washers and threads of bolts (15).
(16) Thickness of 6D740 Thrust Washer (one for each gear) ... .146 ± .002 in.(3.71 ± 0.05 mm)
NOTE: If it is necessary to install a new thrust washer, install all four new thrust washers.
(17) Torque for nuts ... 280 ± 20 lb. ft.(377 ± 25 N·m)
(18) Diameter of the shaft of the spider ... 1.498 ± .001 in.(38.05 ± 0.03 mm)
Bore in bearing ... 1.5050 ± .0005 in.(38.227 ± 0.013 mm)
(24) Thickness of 3D5564 Thrust Washer (one for each side gear) ... .146 ± .002 in.(3.71 ± 0.05 mm)
NOTE: If it is necessary to install a new thrust washer, install both new thrust washers.
NOTE: Adjustments for the differential and bevel gear must be made in the order given.
Adjustment Procedure For The Bevel Pinion Bearings:
1. Install bearings (6) on bevel pinion (12). Install this assembly into carrier assembly (5). Install cage (13) on to carrier assembly (5) with eight bolts (4).
NOTE: Do not install yoke (2), seal (3), or shims (14).
2. Tighten bolts (4) evenly while bevel pinion (12) is turned slowly. Do this until it takes 35 ± 5 lb. in. (4 ± 0.6 N·m) to turn the bevel pinion.
NOTE: To turn th bevel pinion on differentials with two bolts (10), drill a hole and make 5/16 in.- 18 NC threads in the center of collar (1).
3. Install collar (1) to bevel pinion (12) with bolts (10).
4. Install a bolt in the center hole and turn the bolt, collar (1) and bevel pinion (12) with a torque wrench.
5. Use a feeler gauge to measure the distance between cage (13) and carrier assembly (5). Be sure the distance is the same at all points around the cage.
6. Remove cage (13). Install a thickness of shims (14) the same as the distance measured. Install the cage again. Tighten bolts (4) to a torque of 75 ± 5 lb. ft. (100 ± 7 N·m).
7. Check the torque needed to turn the bevel pinion again. Add or remove shims until the torque is 35 ± 5 lb. in. (4 ± 0.6 N·m).
8. Remove cage (13) and install the O-ring seal and seal (3). Put lubricant on the seals.
9. Install cage (13) and bolts (4). Tighten bolts (4) by hand to a torque of 75 ± 10 lb. ft. (100 ± 7 N·m).
10. Install yoke (2), collar (1), the lock and bolts (10). On differentials with one bolt (10), install the collar, flat washer and bolt. Torque for bolt is 265 ± 35 lb. ft. (360 ± 45 N·m).
NOTE: Since the bevel pinion is held stationary in the differential carrier, there is no need to check tooth contact.
Adjustment Procedure For Free Movement (Backlash) Between The Bevel Pinion And The Bevel Gear:
NOTE: Adjustment of the preload on the bearings for the bevel pinion must be made before the differential is installed.
1. Install the differential assembly in carrier assembly (5). Tighten the nuts on the bearing caps. Turn rings (7) and (19) until they are in contact with the bearings. At this time, there must be some free movement (backlash) between the bevel gear and bevel pinion.
2. Put the differential housing on its side so bevel gear (11) is on the bottom and the center line for the axles is in a vertical position.
3. Install a dial indicator on carrier assembly (5) to check the backlash between the bevel gear and bevel pinion. To get the correct backlash, loosen one ring (7) or (19) and tighten the other by the same amount. The correct backlash between the bevel gear and bevel pinion is ... .014 ± .005 in.(0.36 ± 0.13 mm)
Adjustment Procedure For Preload Of The Differential Bearing:
NOTE: Before the adjustment of the bearing preload is started, be sure the nuts on the bearing caps are tight.
1. Use a dial indicator to measure change in dimension (9). Fasten indicator on differential assembly and put pointer on bearing cap.
2. Tighten ring (7) until there is an increase of .020 to .025 in. (0.51 to 0.64 mm) to dimension (9).
3. Turn bevel gear (11) two turns in each direction.
4. Loosen ring (7) until dimension (9) decreases to 0.00 in. (0.0 mm).
5. Tighten ring (7) again until dimension (9) increases to .015 ± .002 in. (0.38 ± 0.05 mm).
6. Again check the backlash between the bevel gear and bevel pinion to be sure it has not changed.
Adjustment Procedure To Get Distance (20), Between Cover (22) And Carrier Assembly (5):
1. Install the differential and carrier into the rear axle housing.
2. Install cover (22). Do not install shims (21).
3. Tighten bolts (23) evenly until cover (22) is against carrier assembly (5). Use a feeler gauge to measure the distance between cover (22) and the rear axle housing.
4. Make a thickness of shims the same as the distance measured plus .002 ± .001 in. (0.05 ± 0.03 mm). Install shims between cover (22) and the rear axle housing.