1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement.
3. Remove the drive pinion yoke and the oil seal. Refer to Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement.




Note:  Do not let the pinion fall out of the rear axle housing.

4. Using the J 22536 driver and a hammer, remove the drive pinion gear.



5. Remove and discard the collapsible spacer.
6. Remove the pinion bearings and the cups. Refer to Drive Pinion Bearings Replacement.
7. Remove the ring gear. Refer to Front Differential Case Disassemble.

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

1. Install the ring gear to the differential case. Refer to Front Differential Case Assemble.
2. Install the drive pinion bearing cups. Refer to Drive Pinion Bearings Replacement.
3. Determine the selective shim thickness for the pinion gear. See Differential Side Bearing Preload Adjustment Procedure below.
4. Install the selective shim onto the pinion.
5. Install the inner pinion bearing onto the pinion. Refer to Drive Pinion Bearings Replacement.



6. Install a new collapsible spacer.
7. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations.
8. Install the pinion to the axle housing.
9. Install the outer pinion bearing.



10. Using the J 21128 installer , install a new pinion oil seal.
11. Apply sealant to the splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers.
12. Install the drive pinion yoke and the oil seal. Refer to Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement

Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.

13. Tighten the pinion nut while holding the J 8614-01 .

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




14. Using an inch-pound torque wrench, measure the rotating torque of the pinion which should be 1.0-2.3 N·m (10-20 lb in) for used bearings or 1.7-3.4 N·m (15-30 lb in) for new bearings..

Note:  Rotate the pinion several times to ensure the bearings have seated.

15. If the rotating torque measurement is less than 1.0 N·m (10 lb in) for used bearings, or 1.7 N·m (15 lb in) for new bearings, continue to tighten the pinion nut in small increments until the torque is 1.0-2.3 N·m (10-20 lb in) for used bearings or 1.7-3.4 N·m (15-30 lb in) for new bearings.
16. Recheck the rotating torque and adjust if necessary.
17. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement.
18. Perform a gear tooth contact pattern check on the pinion and the ring gear. Refer to Gear Tooth Contact Pattern Inspection.
19. Lower the vehicle.

Note: 

1. Install the drive pinion, if necessary. Refer to Drive Pinion and Ring Gear Replacement.

Note: Record the measurement.

2. Using an inch-pound torque wrench, measure the rotating torque of the drive pinion which should be 1.7-3.4 N·m (15-30 lb in) for new bearings or 1.1-2.3 N·m(10-20 lb in) for used bearings.

Note: Before installation of the differential assembly, ensure that the side bearing surfaces in the axle housing are clean and free of burrs. If the original bearings are to be reused, the original bearing cups must also be used.

3. Install the differential assembly with the side bearings and bearing cups into the axle housing.
4. Insert one 4.318 mm (0.170 in) thick service spacer into the left side of the axle housing.
5. Side the differential assembly towards the service spacer in order to hold the spacer in place.
6. Install the J 22779 gage between the right side differential side bearing cup and the axle housing.

Note: Over-tightening may spread the housing and result in incorrect shim selection.

7. Tighten the knob on the J 22779 gage until there is moderate drag when the J 22779 gage is moved.
8. Remove the J 22779 Side Bearing Backlash Gage .
9. Remove the service spacer.
10. Using a micrometer, measure the thickness of the J 22779 gage in 3 locations.

Note: Record the measurement.

11. Calculate the average of the 3 measurements.

Note: Record the measurement.

12. Using a micrometer, measure the thickness of the service spacer.
13. Add the thickness of the service spacer to the average thickness of the J 22779 gage .

The resulting value is the total service shim thickness without preload for the axle.

14. Insert one 1.016 mm (0.040 in) service shim between the right side differential side bearing cup and the axle housing.
15. Insert one BENT 1.016 mm (0.040 in) service shim between the right side differential side bearing cup and the service shim.
16. Install the J 22779 gage on the left side of the differential assembly.
17. While rotating the ring gear back and forth, tighten the knob on the J 22779 gage until there is approximately 0.025-0.051 mm (0.001-0.002 in) of backlash between the ring gear and the drive pinion.
18. Once the amount of backlash is obtained, remove the J 22779 gage .
19. Remove the differential case with the differential side bearings and the bearing cups.
20. Remove the service shims.
21. Using a micrometer, measure the thickness of the J 22779 gage in 3 locations.
22. Calculate the average of the 3 measurements.

This value is the left side service shim thickness without preload.

23. Subtract the service shim thickness for the left side of the axle, calculated in step 22, from the total service shim thickness, calculated in step 13.

This value is the service shim thickness for the right side of the axle without preload.

24. In order to initially set the preload of the differential side bearings and the backlash to approximately 0.013-0.023 mm (0.005-0.009 in), take the value determined in step 23 and add 0.0203 mm (0.008 in) service shim thickness to this amount.
25. Assemble the left side shim pack using one 4.318 mm (0.170 in) service spacer and the appropriate amount of selective service shims equaling the thickness determined in step 22.

Measure the service spacer and the service shims separately.

Add the measurements together in order to determine the total shim pack thickness.

26. Assemble the right side shim pack using one 4.318 mm (0.170 in) service spacer and the appropriate amount of selective service shims equaling the thickness determined in step 24.

Measure the service spacer and the service shims separately.

Add the measurements together in order to determine the total shim pack thickness.

27. Install the differential assembly with the differential side bearings and the differential side bearing cups.
28. Install the left side service spacer between the axle housing and the differential assembly.
29. Install the left side selective service shim or shims.

The service shim or shims must be installed between the service spacer and the differential side bearing cup.

30. Install the right side service spacer between the axle housing and the differential assembly.

Note: The service shim or shims must be installed between the service spacer and the differential side bearing cup.

31. Using the J 25588 installer , install the right side selective service shim or shims.
32. Install the differential bearing caps and the bolts and tighten to 63 N·m (46 lb ft).

Note: 

•	Record the measurement.

•	Rotate the pinion several times to ensure the differential side bearings have seated.

33. Using an inch-pound torque wrench, measure the drive pinion and differential side bearing preload which should be 0.57-1.13 N·m (5-10 lb in) greater than the rotating torque of the drive pinion measured earlier.
34. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured in Step 2, from the drive pinion and differential case bearing preload, measured in Step 32. Multiply the value obtained by the axle ratio it should be 1.7-4.0 N·m (15-35 lb in).
35. If the differential side bearing preload is not within specifications, add or subtract shim thickness equally from each shim pack as necessary in order to increase/decrease the side bearing preload.
36. Once the differential side bearing preload is correct, measure the backlash and adjust, if necessary. Refer to Backlash Inspection and Adjustment.
37. Once the differential side bearing preload and backlash is correct, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to Gear Tooth Contact Pattern Inspection.