Front Differential Case Assemble (9.25 Inch Axle)

Front Differential Case Assemble (9.25 Inch Axle)

Special Tools

* GE-8092 - Universal Driver Handle - 3/4 in - 10

* J-29710 - Differential Side Bearing Installer

* J-36597 - Side Bearing Puller Pilot - 9.25 in Axle

1. Lubricate the pinion and side gears using axle lubricant. Use the correct fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers Front Drive Axle.




2. Install the thrust washers and the differential side gears into the differential case.
If the same differential side gears and the thrust washers are being used, install the gears and the washers to the original locations.




3. Install the differential pinion gears by performing the following steps:

1. Position both pinion gears between the differential side gears directly opposite of each other.

2. Rotate the differential side gears until the pinion gears are opposite the opening in the differential case in line with the pinion shaft opening.

4. Install the thrust washers in between the pinion gear and differential case using a hammer and brass drift.

5. Install the differential side gear spacers.




6. Install the pinion gear shaft.





Caution: Refer to Fastener Caution Fastener Caution.

7. Install the pinion shaft lock bolt and tighten to 53 Nm (39 lb ft).





Note: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

8. Install the ring gear onto the differential case.





Note: The ring gear bolts have left-hand threads.

9. Install the new ring gear bolts.
Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

10. Install the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten the ring gear bolts in sequence to 138 Nm (102 lb ft).




11. Install the differential side bearings by performing the following steps:

1. In order to protect the differential case, install the J-36597 - side bearing puller pilot in the case on the side opposite the bearing installation.

2. Install the J-29710 - differential side bearing installer (2) and the GE-8092 - universal driver handle (1) onto the differential case bearing as shown.

3. Drive the differential case bearing onto the case using the J-29710 - differential side bearing installer and the GE-8092 - universal driver handle.