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Diagnosis and repair



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1.Place side gear thrust washer and side gear in differential case bore, Fig. 10. Liberally lubricate all differential components with suitable lubricant during assembly.
2.Using soft faced hammer, drive differential pinion shaft into case only far enough to retain pinion thrust washer and pinion gear.
3.Place second differential pinion and thrust washer in position and drive pinion shaft into place, carefully aligning pinion shaft lockpin holes.
4.Place second side gear and thrust washer in position and install pinion shaft lockpin and the cover on differential case then insert axle shaft spline in side gear spline to check for free rotation of differential gears.
5.Using suitable solvent, clean tapped holes in ring gear.
6.Insert two 7/16 N.F. bolts two inches long through differential case flange and thread them three or four turns into ring gear as a guide for aligning ring gear bolts, then press or tap ring gear into position. If new bolts show a green or yellow coating of at least 1/2 inch on threaded area, use as is. If bolts are not coated, apply small amount of suitable sealant to threads. Torque bolts to specifications. Never install used bolts.
7.If differential bearings were removed, press them on using Bearing Cone Installation tool No. T57L-4221-A2 or equivalent.
8.Wipe thin coating of suitable lubricant on carrier differential bearing bores, then place cups on bearings and set differential case assembly in carrier.
9.Assemble differential case and ring gear assembly in carrier so that marked tooth on drive pinion indexes between marked teeth on ring gear.
10.Slide assembly along bores until a slight amount of backlash is felt between gear teeth.
11.Set adjusting nuts in bores so that they just contact bearing cups, engaging nuts approximately the same number of threads on both sides.
12.Carefully position differential bearing caps on carrier, matching alignment marks.
13.Ensure that adjuster nuts are properly threaded in cap and carrier and that they turn freely, then install bearing caps and alternately torque them to specifications.
14.If adjusting nuts do not turn freely as cap bolts are tightened, remove differential bearing caps and inspect for damaged threads or incorrectly positioned caps.
15.Adjust backlash and differential bearing preload.
Fig. 10 Assembling Differential CaseFig. 10 Assembling Differential Case


1.Place side gear thrust washer and side gear in differential case bore, Fig. 10. Liberally lubricate all differential components with suitable lubricant during assembly.
2.Using soft faced hammer, drive differential pinion shaft into case only far enough to retain pinion thrust washer and pinion gear.
3.Place second differential pinion and thrust washer in position and drive pinion shaft into place, carefully aligning pinion shaft lockpin holes.
4.Place second side gear and thrust washer in position and install pinion shaft lockpin and the cover on differential case then insert axle shaft spline in side gear spline to check for free rotation of differential gears.
5.Using suitable solvent, clean tapped holes in ring gear.
6.Insert two 7/16 N.F. bolts two inches long through differential case flange and thread them three or four turns into ring gear as a guide for aligning ring gear bolts, then press or tap ring gear into position. If new bolts show a green or yellow coating of at least 1/2 inch on threaded area, use as is. If bolts are not coated, apply small amount of suitable sealant to threads. Torque bolts to specifications. Never install used bolts.
7.If differential bearings were removed, press them on using Bearing Cone Installation tool No. T57L-4221-A2 or equivalent.
8.Wipe thin coating of suitable lubricant on carrier differential bearing bores, then place cups on bearings and set differential case assembly in carrier.
9.Assemble differential case and ring gear assembly in carrier so that marked tooth on drive pinion indexes between marked teeth on ring gear.
10.Slide assembly along bores until a slight amount of backlash is felt between gear teeth.
11.Set adjusting nuts in bores so that they just contact bearing cups, engaging nuts approximately the same number of threads on both sides.
12.Carefully position differential bearing caps on carrier, matching alignment marks.
13.Ensure that adjuster nuts are properly threaded in cap and carrier and that they turn freely, then install bearing caps and alternately torque them to specifications.
14.If adjusting nuts do not turn freely as cap bolts are tightened, remove differential bearing caps and inspect for damaged threads or incorrectly positioned caps.
15.Adjust backlash and differential bearing preload.



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