Manual Transmissions: Differential: Assembly: Notes

Assemble side gears, pinion gears and thrust washers (Figure) into case through opening and rotating into position.
Install pinion shaft. (Figure).
Using hammer and suitable punch, install pinion shaft retaining pin. (Fig 1).

Fig 1: Installing Retaining Pin
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Stake case to retain pin as shown in (Fig 2).

Fig 2: Staking Retaining Pin
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Using an arbor press, Handle C-4171, and Tool L-4410, install differential side bearings to ring gear and case side. (Fig 3 and Fig 4 ).

Fig 3: Installing Differential Bearing Cone To Differential. Case Side
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Fig 4: Installing Differential Bearing Cone To Ring Gear Side
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Install speedometer drive gear to case. (Fig 5).

Fig 5: Installing Speedometer Drive Gear
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Using an arbor press, steel block, and Tool L-4440, press speedometer drive gear onto differential case. (Fig 6 and Fig 7 ).

Fig 6: Positioning Drive Gear On Differential
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Fig 7: Pressing Drive Gear Onto Differential
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Install ring gear to differential case. Install new bolts and torque to 81 N.m (60 ft. lbs.). (Fig 8).

Fig 8: Installing Ring Gear & Bolts
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