Tools Required

1. Install the outer bearing into the case using the J 33837 -1, the J 33837 -3, and the J 33837 -4.



2. Install the inner and outer bearing race into the carrier using the J 33837 -1, the J 33837 -3, and the J 33837 -4.
3. Adjust the pinion depth by selecting a shim of the proper thickness.
4. Lubricate the inner and outer pinion bearings liberally using axle lubricant.



5. Hold the pinion bearings in position and install the J 33838 .



6. Install the J 29763 .

6.1.	Set the J 29763 at ZERO.

6.2.	Position the J 29763 in the J 33838 .

6.3.	Push the J 29763 downward until the needle rotates approximately 3/4 turns to the right.

7. Tighten the dial indicator in this position.



8. Set the button of the J 33838 on the differential bearing bore.
9. Rotate the tool slowly back and forth until the J 29763 reads the lowest point of the bore. Set the J 29763 to ZERO. Repeat the rocking action of the tool in order to verify the ZERO setting.



10. After you obtain and verify the ZERO setting, move the tool button out of the differential side bearing bore. Record the J 29763 reading.

The J 29763 reading equals the shim size. For example, if the J 29763 reads 0.84 mm (0.003 in) in step 8, a 0.84 mm (0.003 in) shim is required.

11. Remove the tools and bearing cones.



12. Install the selective shim between the inner bearing and the gear shoulder.
13. Install the inner pinion bearing onto the pinion gear using the J 33785 .
14. Install a new collapsible spacer onto the pinion gear.
15. Lubricate the pinion bearings using axle lubricant.
16. Install the outer pinion bearing into the carrier.



17. Install the pinion seal using the J 33782 .
18. Install the pinion gear (with the inner bearing and the spacer) into the carrier.
19. Apply sealant to the inside sealing surface of the pinion yoke.
20. Apply special seal lubricant to the outside sealing surface of 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.

Important: Install the pinion yoke in the same position as marked during removal in order to maintain driveline balance.

21. Install the drive pinion yoke by tapping the yoke using a soft-faced hammer until a few pinion shaft threads show through the yoke. The pinion will need to be held in place from inside the carrier half.




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.

Important: Reference the number of exposed threads on the pinion stem recorded during removal.

22. Install the washer and a new nut using the J 8614-01 .

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





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

23. Measure the pinion bearing preload using an inch-pound torque wrench.

23.1.

Rotate the pinion with the torque wrench and observe the reading.

23.2.

The correct preload is 1.7-2.8 N·m (15-25 lb in).

Tighten
Tighten the nut in small increments, as needed, until the preload is correct.

24. Once the specified preload is obtained, rotate the pinion several times in order to ensure the bearings are seated. Recheck the preload and adjust if necessary.
25. Install the thrust washers and side gears into the differential case. If reusing the original gears and washers, install the gears on the same side from which the parts were removed.
26. Install the pinion gears.

26.1.

Position one pinion gear between the side gears. Rotate the gears until the pinion gear is directly opposite the opening in the case.

26.2.

Place the other gear between the side gears. Ensure that the holes in both pinion gears are aligned.

27. Install the thrust washers. Rotate the pinion gears toward the opening in order to permit the thrust washers to slide in.
28. Install the shaft and the bolt.
29. Install the ring gear onto the differential case.

Important: Always install new bolts. Do not reuse the old bolts.

30. Install the ring gear mounting bolts.

Tighten
Tighten the bolts, in progressive steps, to 80 N·m (59 lb ft).




31. Install the side bearings using the J 8092 and the J 33790 .



32. Install the bearing into the right sleeve using the J 33788 .



33. Install the bearing into the left sleeve using the J 42211 .
34. Install the sleeves into the carrier. Thread the sleeves in completely.



35. Install the side bearing cups into the carrier using the J 23423-A and the J 8092 .



36. Install the differential case assembly to the carrier.

36.1.

Place the differential case assembly into the carrier half that contains the pinion gear.

36.2.

Turn the left sleeve in toward the differential case using the J 42213 until backlash is felt between the ring and pinion gear.

37. Assemble the carrier halves. Do not use sealer at this time.



38. If the carrier halves do not contact completely, back out the right hand adjusting sleeve. Use the J 33792 .
39. Install the four carrier halves assembly bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

40. Inspect and adjust the backlash. Refer to Backlash Inspection and Adjustment .
41. Inspect the gear tooth contact pattern. Refer to Gear Tooth Contact Pattern Inspection .
42. Remove the 4 case bolts.
43. Remove the right carrier case half.
44. Clean the sealing surfaces on the carrier case halves. Remove all oil and grease using a chlorinated solvent, such as carburetor cleaner.
45. Apply a bead of sealer to one carrier half mounting surface.
46. Assemble the carrier halves.
47. Install the carrier halves assembly bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

48. Ensure that the sleeves are positioned properly, as previously marked.



49. Install the bolts and lock tabs.

Tighten
Tighten the bolts to 8 N·m (71 lb in).

50. Clean all oil and grease from the left cover and seal assembly, the bolts and the carrier sealing surfaces using carburetor cleaner or equivalent.
51. Install the left cover and seal assembly.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).




52. Install the bearing using the J 42211 and the J 8092 .



53. Install the shaft seal using the J 23911 .



54. Install the shift housing seal using the J 33799 .



55. Install the clutch shaft pilot bearing using the J 33842 .
56. Install the washer to the clutch shaft.
57. Install the clutch shaft to the carrier assembly.
58. Install the clutch sleeve.
59. Install the thrust washer using grease in order to secure.
60. Install the spring with the shift shaft and fork.



61. Install the thrust washer using grease in order to secure. Align the notch and tab.
62. Install the inner axle shaft to the housing.
63. Install the clutch gear with the retaining ring. Tap into place.

63.1.

Remove all oil and grease from the housing flange to carrier gasket surfaces using carburetor cleaner or equivalent.

63.2.

Apply sealer to the carrier.

64. Install the shaft and housing assembly to the carrier.
65. Install the two upper bolts finger-tight.
66. Install the shift cable housing and the remaining bolts.

Tighten
Tighten the five bolts to 48 N·m (36 lb ft).




67. Install the bushings using the J 33791 -1, the J 33791 -2 and the J 33791 -3.



68. Inspect the operation of the shift mechanism. Insert the J 33798 into the shift fork.
69. Turn the axle shaft while engaging and disengaging the shift mechanism with the tool.
70. The mechanism should operate smoothly. If not, remove the tube. Inspect for damaged or improperly installed parts.